Engine Synchro Shift (ESS ) Transmissiongraphicvillage.org/meritor/MM9850.pdf · Engine Synchro...

Revised 6-99$2.50

Engine Synchro Shift™

(ESS™) TransmissionWith ZF Meritor’s Transmission

Control Unit (TCU) Maintenance and Diagnostics

Manual No. MM-9850

WE SUPPORTVOLUNTARY TECHNICIAN

CERTIFICATIONTHROUGH

TM

Service Notes

-iii

Service Notes

This publication provides maintenance and service procedures for ZF Meritor’s Engine Synchro Shift

TM

(ESS

TM

) transmission with a transmission control unit (TCU). The information contained in this publication was current at the time of printing and is subject to revision without notice or liability.

1. You must understand all procedures and instructions before you begin maintenance and service procedures.

2. You must follow your company’s maintenance and service guidelines.

3. You must use special tools, when required, to avoid serious personal injury and damage to components.

Meritor uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components.

Visit Our Web Site

Visit the Technical Library section of

www.meritorauto.com

for additional product and service information on Meritor’s heavy vehicle systems component lineup.

Technical Electronic Library

on CD

The CD includes product and service information on Meritor’s component lineup. $20. Order TP-9853.

Additional ESS

TM

Information

r

Engine Synchro Shift

TM

Operator Manual

(TP-95130)

r


TM

Operator Manual

and

On the Road with ESS

TM

audio tape (TP-95130A)

r

Driving is Easy with ESS

TM

laminated card (TP-96118)

r

Wiring Diagram for an ESS

TM

Transmission with Meritor’s Transmission Control Unit (TCU)

(TP-9851)

Video


TM

Transmission

(VIDEO T-95203V). $20.

How to Order

Call Meritor’s Customer Service Center at 800-535-5560.

WARNING

A WARNING indicates a procedure that you must follow exactly to avoid seriouspersonal injury.

CAUTION

A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components. Serious personal injury can also occur.

NOTE:

A

NOTE

indicates an operation, procedure or instruction that is important for proper service. A

NOTE

can also supply information that will help to make service quicker and easier.

This symbol indicates that you must tighten fasteners to a specific torque.

Table of Contents

ESS

TM

Transmission Models

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Section 1: Introduction

Engine Synchro Shift™ (ESS™) Transmission Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Synchronizes the Transmission

Shifting Gears

Automated HIGH and LOW Range

Break Torque

ESS™ System Components

How ZF Meritor’s Engine Synchro Shift™ (ESS™) System Works

On the Shift Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

The System Switch

The Shift Intent Switch

How to Shift

To Start the Vehicle

Shift Into a Starting Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

The ESS™ System Safety Feature: The “Time-Out Sequence”

Upshifting Into the Next Higher Gear

Upshifting Into the Rest of the Gears

If a Gear “Partially Engages” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

To “Skip Shift”

Downshifting Into the Next Lower Gear

Downshifting Into the Rest of the Gears

If a Gear “Partially Engages”

To “Skip Shift”

Shift Into REVERSE (R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Shift Into HIGH Range REVERSE

ESS™

Transmission Cab Shift Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Section 2: Flash Code Diagnostics

Flash Codes and Volt-Ohm Meter (VOM) Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Questions and Answers About Flash Codes and System Faults

Activating TCU Flash Code Diagnostics

OEM-Installed “Check Transmission” Light and Toggle Switch

How the “Check Transmission” Light Displays Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Record the Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

How to Read Flash Codes

How to Clear Flash Codes from TCU Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Testing ESS™ System Conditions That Do Not Have Flash Codes (NO ACTIVE CODE)

Wire Splicing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Required Tools

Apply Dielectric Grease to Range Solenoid Pin Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Shift Knob Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Table of Contents

Shift Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Switch Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Vehicle Speed Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Wiring Harness Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Shift Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Vehicle Speed Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Switch Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Shift Knob Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Section 3: Pro-Link

®

9000 Diagnostics

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

ESS™ System Diagnostics Using the Pro-Link

®

9000 Diagnostic Data Reader (DDR) with ZF Meritor’s ESS™ PCMCIA Card

Non-Volatile Memory Cartridge Means No Lost Data

Stored Data That Is Retrievable

Readout Window

Keypad and Key Functions

Keypad

Ten Numeric Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Four Arrow Keys

Function Key (FUNC)

ENTER Key

Installing the Multi-Protocol Cartridge (MPC) Into the Pro-Link

®

9000 DDR

Installing the PCMCIA Card Into the MPC

Removing the PCMCIA Card

Display Data Line (DDL) Cable Connection

What to Check if the Pro-Link

®

9000 DDR Does Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

System Selection

System Selection Process

Copyright Screen

Data Display

Data Readout

Recall Data

NO DATA Readout

“Data Freeze” Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

To Freeze a Line of Data

To Unfreeze One Line of Data

To Unfreeze All Lines at Once

How to Retrieve Data Stored in the Pro-Link

®

9000 DDR Without Using the Vehicle’s DDL . . . . . . . . . 48

How to Open the ESS™ System Application

Install the MPC Application Card

Connect the Pro-Link

®

9000 DDR to the Vehicle’s Diagnostic Data Line (DDL) Cable

Table of Contents

“ZF Meritor ESS” Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

How to Access “ZF Meritor ESS” Menu Options

“Fault Codes” Option

“Performance Data” Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

“Calibration Identification (ID)” Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

“Component Tests” Option

“View ESS” Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

“Change ESS” Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

“ESS Trip Data” Options

“Axle Ratio” Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

“Torque Control” Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

How to Use the Pro-Link

®

9000 DDR to Test ESS™ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Open the ESS™ Application

Testing ESS™ Components

Transmission Control Unit (TCU): Fault Code 254

ESS™ Shift Knob: Fault Code 227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

ESS™ High and Low Range Shift Solenoids: Fault Codes 35 and 36 . . . . . . . . . . . . . . . . . . . . . . . . . . .59

ESS™ Switch Assembly (Neutral and In Gear Switches): Fault Code 226 . . . . . . . . . . . . . . . . . . . . . . .60

ESS™ Vehicle Speed Sensor (VSS): Fault Code 191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Section 4: Wiring Diagram and Component Overview

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Section 5: Removal and Installation

TCU Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

TCU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Shift Knob Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Shift Knob Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Wiring Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Top Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Overhauling the Top Cover Housing: Standard and Forward Positions . . . . . . . . . . . . . . . . . . . . . . . . .83

Range Cylinder Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Range Cylinder Solenoid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Switch Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Switch Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Vehicle Speed Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Vehicle Speed Sensor Installation

Neutral Check Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Neutral Check Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Range Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Range Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

ESS

TM

Transmission Models

i

ESS

TM

Transmission Models

Torque Rating(lb-ft)

11 = 115012 = 125013 = 135014 = 145015 = 155016 = 1650

M O F E 18* FPR

ZF Meritor

1016 C

* Progressive torque is an engine feature that requires aTorq-2TM transmission. In models not featuring progressive torque, this number will be the same as the torque rating.

9 = 9-Speed10 = 10-Speed13 = 13-Speed

RatioABCR

Highest torquein top two gears

16 = 1650 lb-ft18 = 1850 lb-ft

E = ESSTM (Meritor TCU)D = ESSTM (DDC ECM)S = SureShiftTM

M = Manual

Design Platform

O = OverdriveNo Letter = D/D

Section 1Introduction

1



TM

(ESS

TM

) Transmission Features

Synchronizes the Transmission

r

The Engine Synchro Shift

TM

(ESS

TM

) system automatically synchronizes the transmissionby matching engine rpm to the vehicle’s road speed.

Shifting Gears

r

With the ESS

TM

system you only use the clutch pedal to START and STOP the vehicle or to shift into FORWARD or REVERSE. If you use the clutch while driving, the ESS

TM

system becomes inactive, and you will have manual control of the transmission.

Automated HIGH and LOW Range

r

Range shifts are automatic, which means you do not have to preselect HIGH or LOW ranges.

Break Torque

r

You can move the shift lever out of gear WITHOUT changing throttle position. The ESS

TM

system will automatically synchronize engine rpm to road speed.

r

With the ESS

TM

system you can apply the service brake as you downshift through the gears when you are stopping the vehicle.

r

On steep grades, the ESS

TM

system allows you to maintain throttle position WITHOUT

usingthe clutch.

ESS

TM

System Components

r

System switch

r

Shift Intent switch

r

Speed sensors for transmission input and output shafts

r

NEUTRAL (N) position sensor

r

Electropneumatic solenoids (located in the transmission)

r

In gear position sensor

How ZF Meritor’s Engine Synchro Shift

TM

(ESS

TM

) System Works

The ZF Meritor Engine Synchro Shift

TM

(ESS

TM

) system collects and relays the following information to the transmission control unit (TCU):

r

The positions of the system switch and the shift intent switch

r

The speeds of the transmission input shaft and output shaft

r

The position of the shift lever in the shift tower.

The TCU processes the information and relays the data to the engine control module (ECM). The ECM increases or decreases engine rpm to match the vehicle’s road speed. The TCU also controls the HIGH or LOW range selection in the auxiliary case on the rear of the transmission.

ENGINESENSORS

ECM

SHIFT KNOB

OUTPUTSPEED

INPUT RPMENGINE TORQUE

TCU

NEUTRAL SW.IN GEAR SW.

RANGESOLENOIDS


2

On the Shift Knob

The System Switch

The two-position system switch, the lowest switch on the operator’s side of the shift knob, turns the ESS

TM

system ON and OFF and displays the system status.

r

When you slide the system switch DOWN, you see the word “ON.” This means that the ESS

TM

system is activated.

r

When you slide the switch UP, you see the word “OFF.” This means that the ESS

TM

system is not activated, and you have manual control of the transmission.

The Shift Intent Switch

r

The shift intent switch is a four-position rocker switch located above the system switch on the operator’s side of the shift knob.

r

When the ESS

TM

system is turned ON, the shift intent switch signals the ECM that you will UPSHIFT or DOWNSHIFT, based on your input.

r

You can also use the shift intent switch to release torque on the gears — break torque — just before you shift. Just press the switch all the way in to the end of its travel, and then release it without changing throttle position.

r

When the ESS

TM

system is OFF (which means that system is inactive), you have manual control of the transmission. The shift intent switch acts as a range selector.

r

To preselect range shifts

: While in gear, press the TOP of the shift intent switch for HIGH range and the BOTTOM of the switch for LOW range.

How to Shift

WARNING

The transmission must be in the NEUTRAL (N)

position when you start the vehicle. If you start the vehicle with the transmission in gear, the vehicle will suddenly move FORWARD or REARWARD. Serious personal injury and damage to the transmission can result.

To Start the Vehicle

1. Check that the shift lever is in the NEUTRAL (N) position.

2. Push the clutch pedal to the bottom of travel to engage the clutch brake.

3. Start the engine.

4. Slowly release the clutch pedal.

5. Allow the air pressure in the air system to reach the specified range on the gauge.

6. Release the parking brakes.

SHIFT KNOB

“ON” ESSTM SYSTEM

“OFF” MANUAL SHIFT

SYSTEM SWITCH

SHIFT KNOB

SHIFT INTENT SWITCH

1. UPSHIFTS2. BREAK TORQUE (UP)3. DOWNSHIFTS4. BREAK TORQUE (DOWN)

FOUR POSITIONS:


3

Shift Into a Starting Gear

1. Turn ON (activate) the ESS

TM

System:

r

Slide the two-position system switch (the lowest switch on the operator’s side of the shift knob) DOWN. You will see the word “ON,” which means that the ESS

TM

system is activated.

CAUTION

Use the clutch brake only for initial gear engagement when the vehicle is stationary to avoid damage to the input shaft and/or the clutch brake.

2. Disengage the Clutch:

r

Push the clutch pedal to the bottom of travel. (The clutch brake will touch the clutch release bearing.) Clutch disengagement stops the transmission for initial gear engagement.

CAUTION

Always use the correct starting gear when you operate the transmission. Do not shift into NEUTRAL and coast. Damage to the transmission can result.

3. Shift Into a Starting Gear:

r

With the clutch pedal at the bottom of travel, move the shift lever into a starting gear.

r

Slowly release the clutch pedal to move the vehicle FORWARD.

The ESS

TM

System Safety Feature: The “Time-Out Sequence”

The ESS

TM

system has a built-in safety feature called the “time-out” sequence. If you do not complete a shift from NEUTRAL (N) within three seconds after you break torque, the system becomes inactive — or “times-out” — and returns the transmission to manual control.

To turn

ON

(reactivate) the ESS

TM

system so that you can continue to shift:

r

Press the shift intent switch again. (Refer to the “Upshifting” and “Downshifting” sections in this manual for instructions on how to use the shift intent switch.)

Upshifting Into the Next Higher Gear

NOTE:

Expect a DROP in rpm when you UPSHIFT.

1. Press the TOP of the shift intent switch

once

for first shift. This signals the ESS

TM

system that you will UPSHIFT. Then move UP through the gears without pressing the switch again.

Figure A

.

2. To break engine torque, continue to press the TOP of the shift intent switch all the way in to the end of its travel and then release it, which enables the shift lever to move freely out of gear.

Figure B

.

NOTE:

When you shift, do not rush or try to “beat” the system. If you experience “gear clashing,” you have shifted too fast. Just shift at a natural pace or speed.

3.

Immediately

move the shift lever into NEUTRAL (N) and pause for a second. The ESS

TM

system will slow down the engine to the correct rpm and synchronize the transmission to road speed.

4. Move the shift lever into the next HIGHER gear.

Upshifting Into the Rest of the Gears

1. Press the TOP of the shift intent switch all the way in to the end of its travel and then release it each time you move the shift lever. The range shift is automatic.

2. Repeat Steps 1 through 4.

A B


4


1. Press the shift intent switch all the way in to the end of its travel and then release it.

2. Move the shift lever into the next HIGHER gear.

To “Skip Shift”

NOTE:

“Skip shifting” causes a change in engine speed. Pause longer in NEUTRAL (N).

1. Pause longer in NEUTRAL (N) to let the ESS

TM

system synchronize the transmission.

2. Press the shift intent switch

once

for each gear you want to skip.

Downshifting Into the Next Lower Gear

NOTE:

Expect a RISE in rpm when you DOWNSHIFT.

1. Press the BOTTOM of the shift intent switch

once

for first shift. This signals the ESS

TM

system that you will DOWNSHIFT. Then move DOWN through the gears without pressing the switch again.

Figure C

.

2. To break engine torque, continue to press the BOTTOM of the shift intent switch all the way in to the end of its travel and then release it, which enables the shift lever to move freely out of gear.

Figure D

.

NOTE:

When you shift, don’t rush or try to “beat” the system. If you experience “gear clashing,” you have shifted too fast. Just shift at a natural pace or speed.

3.

Immediately

move the shift lever into NEUTRAL (N) and pause for a second. The ESS

TM

system will slow down the engine to the correct rpm and synchronize the transmission to road speed.

4. Move the shift lever into the next LOWER gear.

Downshifting Into the Rest of the Gears

1. Press the BOTTOM of the shift intent switch all the way in to the end of its travel and then release it each time you move the shift lever. The range shift is automatic.

2. Repeat Steps 1 through 4.


1. Press the shift intent switch all the way in to the end of its travel and then release it.

2. Move the shift lever into the next LOWER gear.

To “Skip Shift”

NOTE:

“Skip shifting” causes a change in engine speed. Pause longer in NEUTRAL (N).

1. Pause longer in NEUTRAL (N) to let the ESS

TM

system synchronize the transmission.

2. Press the shift intent switch

once

for each gear you want to skip.

C D


5

Shift Into REVERSE (R)1. Turn ON (activate) the ESSTM System:

r Slide the two-position system switch (the lowest switch on the operator’s side of the shift knob) DOWN. You will see the word “ON,” which means that the ESSTM systemis activated.

CAUTIONUse the clutch brake only for initial gear engagement when the vehicle is stationary to avoid damage to the input shaft and/or the clutch brake.


r Push the clutch pedal to the bottom of travel. (The clutch brake will touch the clutch release bearing.) Clutch disengagement stops the transmission for initial gear engagement.

3. Shift Into REVERSE (R):

r With the clutch pedal at the bottom of travel, move the shift lever into REVERSE (R).

r Slowly release the clutch pedal to move the vehicle in the reverse direction.

Shift Into HIGH Range REVERSE1. Turn OFF (Deactivate) the ESSTM System:

r Slide the two-position system switch (the lowest switch on the operator’s side of the shift knob) UP. You will see the word “OFF,” which means that ESSTM is turned OFF, or deactivated.

2. Preselect HIGH Range:

r With the shift lever in gear, press the TOP of the shift intent switch to put the transmission into HIGH range.

CAUTIONUse the clutch brake only for initial gear engagement when the vehicle is stationary to avoid damage to the input shaft and/or the clutch brake.


r Push the clutch pedal to the bottom of travel. (The clutch brake will touch the clutch release bearing.) Clutch disengagement stops the transmission for initial gear engagement.

4. Shift Into REVERSE (R):

r With the clutch pedal at the bottom of travel, move the shift lever into REVERSE (R).

r Slowly release the clutch pedal to move the vehicle in the reverse direction.


6

ESS

TM

Transmission Cab Shift Labels

CAUTION

Shift patterns vary by vehicle. You must use the correct shift pattern for the vehicle you operate to avoid damage to the transmission.

1. Refer to the shift pattern decal affixed to the sun visor or instrument panel when you shift the transmission.

2. If the decal is missing or unreadable, call Meritor’s Florence Distribution Center at 888-725-9355/Option #5 to order a new decal.

3. Install the new decal in the vehicle.

r

9-speed standard models.

Figure 1.1

.

r

9-speed R-Ratio models.

Figure 1.2

.

r

10-speed models.

Figure 1.3

.

Figure 1.1

TO ACTIVATE ESS:• Turn system switch to ON• Depress clutch pedal• Select starting gear

TO UP-SHIFT:• Fully depress shift intent switch UP and release• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into higher gear 1-2-3-4-5-6-7-8

TO DOWN-SHIFT:• Fully depress shift intent switch DOWN and release• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into lower gear 7-6-5-4-3-2-1-LO

CLUTCH USE:• Use clutch only for starting and stopping• Depressing clutch disables engine synchronization• System OFF requires use of clutch for shifting

NOTE: System switch OFF activates manual control.• Preselect shift intent switch DOWN for low range.• Preselect shift intent switch UP for hi range.• Do not select range in NEUTRAL. Preselect in gear.• Do not range shift while moving in REVERSE. 2

297-A

-7125

ENGINE SYNCHRO SHIFT

SYSTEM SWITCH

SHIFT INTENT

SWITCH

• UPSHIFT

– Fully depress top

• DOWNSHIFT

– Fully depress bottom

Standard

9-SpeedTransmission

RR

51

73

62

84

N

LO

Refer to TP-95130 for more information

2297-Q

-7245


SYSTEM SWITCH

SHIFT INTENT

SWITCH

• UPSHIFT


• DOWNSHIFT


Standard

9-SpeedTransmission


CLUTCH USE:• Use clutch only for starting

and stopping• Depressing clutch disables engine

synchronization• System OFF requires use of clutch

for shifting

NOTE: System switch OFF activates manual control.• Preselect shift intent switch DOWN

for low range.• Preselect shift intent switch UP for

hi range.• Do not select range in NEUTRAL.

Preselect in gear.• Do not range shift while moving

in REVERSE.

TO UP-SHIFT:• Fully depress shift intent switch UP

and release• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into higher gear

1-2-3-4-5-6-7-8

• Fully depress shift intent switch DOWNand release

• Immediately move lever to NEUTRAL• Let engine synchronize• Move lever into lower gear

7-6-5-4-3-2-1-LO

TO DOWN-SHIFT:


RR

51

73

62

84

N

LO

Figure 1.2

Figure 1.3


TO UP-SHIFT:• Fully depress shift intent switch UP and release• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into higher gear 2-3-4-5-6-7-8-9

TO DOWN-SHIFT:• Fully depress shift intent switch DOWN and release• Immediately move lever to NEUTRAL• Let engine synchronize• Move lever into lower gear 8-7-6-5-4-3-2-1



297-C

-7127


SYSTEM SWITCH

SHIFT INTENT

SWITCH

• UPSHIFT


• DOWNSHIFT


R-Ratio

9-SpeedTransmission

RR

62

84

73

51 9

N


2297-S

-7247


SYSTEM SWITCH

SHIFT INTENT

SWITCH

• UPSHIFT


• DOWNSHIFT


R-Ratio

9-SpeedTransmission





for shifting





in REVERSE.



2-3-4-5-6-7-8-9


• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into lower gear

8-7-6-5-4-3-2-1

TO DOWN-SHIFT:


RR

62

84

73

51 9

N


TO UP-SHIFT:• Fully depress shift intent switch UP and release• Immediately move lever to NEUTRAL• Let engine synchronize• Move lever into higher gear 2-3-4-5-6-7-8-9-10

TO DOWN-SHIFT:• Fully depress shift intent switch DOWN and release• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into lower gear 9-8-7-6-5-4-3-2-1



297-B

-7126


SYSTEM SWITCH

SHIFT INTENT

SWITCH

• UPSHIFT


• DOWNSHIFT


10-SpeedTransmission

RR

72

94

83

105

N

61


2297-R

-7246


SYSTEM SWITCH

SHIFT INTENT

SWITCH

• UPSHIFT


• DOWNSHIFT


10-SpeedTransmission

RR

72

94

83

105

N

61





for shifting





in REVERSE.



2-3-4-5-6-7-8-9-10


• Immediately move lever to NEUTRAL • Let engine synchronize• Move lever into lower gear

9-8-7-6-5-4-3-2-1

TO DOWN-SHIFT:


Section 2Flash Code Diagnostics

7

Section 2Section 2Flash Code Diagnostics

WARNING

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

When you work on an electrical system, the possibility of electrical shock exists, and sparks can ignite flammable substances. You must always disconnect the battery ground cable before you work on an electrical system to prevent serious personal injury and damage to components.

Flash Codes and Volt-Ohm Meter (VOM) Diagnostics

The Transmission Control Unit (TCU) uses sequences of light flashes called flash codes to identify faults that the TCU detects and stores into memory. After you identify the fault by observing the flash code, use the VOM to test the area where the flash code indicates that the fault has occurred. An authorized Meritor distributor/dealer should repair the fault.

There are faults that can occur in the ESS

TM

system that flash codes will identify. Each fault has its own sequence of light flashes (flash code).

Questions and Answers About Flash Codes and System Faults

What are flash codes?

ZF Meritor’s transmission control unit (TCU) uses sequences of light flashes called flash codes to identify faults that the TCU detects and stores into memory.

What is a “fault”?

A “fault” is a problem that currently exists in the ESS

TM

system or system components.

Does each fault have its own flash code?

Yes. For example, Flash Code 36 identifies a voltage fault in the low range solenoid. Refer to the table in this section for a list of flash codes and fault descriptions.

How do you retrieve flash codes from the TCU?

Use the “Check Transmission” light and toggle switch, an optional OEM installation that is usually located on the dashboard near the check engine light. The toggle switch activates the “Check Transmission” light to identify ESS

TM

system faults.

In what order does the TCU store faults?

The TCU stores faults in the order that they occur.

When should you clear flash codes from TCU memory?

Repair all faults before you clear flash codes from TCU memory.

What happens if you repair a fault but do not clear it from TCU memory?

The fault will remain in the TCU as an inactive fault. The next time you perform flash code diagnostics:

r

Test the area to confirm that the fault has been repaired. If there are other faults in TCU memory, repair the faults.

r

Clear the repaired faults from TCU memory.

Who should repair a fault in the ESS

TM

system?

A ZF Meritor-authorized technician should repairthe fault.

Activating TCU Flash Code Diagnostics

OEM-Installed “Check Transmission” Light and Toggle Switch

NOTE:

If a “Check Transmission” light and toggle switch are not installed in the vehicle, call Meritor’s Customer Service Center at 800-535-5560 for assistance.

1. With the ignition OFF, PRESS and HOLD the ESS

TM

diagnostic toggle switch.

2. Turn the ignition ON, but do not start the engine.

3. Release the ESS

TM

diagnostic toggle switch three seconds after turning the ignition ON. The TCU activates and begins a self-diagnostic check of the system. The “Check Transmission” light will flash to verify that the system is operating correctly.


8

How the “Check Transmission” Light Displays Flash Codes

NOTE:

The “Check Transmission” light continues to display flash codes until you turn the ignition OFF. Flash codes will remain in TCU memory until you clear them.

1. After the TCU checks the system, the “Check Transmission” light pauses for about three seconds.

2. The “Check Transmission” light then begins to consecutively display faults in two- or three-digit flash code sequences, with a short pause between each digit and a longer pause between each sequence.

r

An example of a two-digit fault is Flash Code 36, a fault in the low range solenoid. For this fault, the “Check Transmission” light would display the two-digit flash code as

3-6

.

Figure 2.1

.

r

An example of a three-digit fault is Flash Code 226, an ESS

TM

switch assembly fault. For this fault, the “Check Transmission” light would display the three-digit flash code

2-2-6

.

Figure 2.1

.

3.

If the TCU has stored only one fault into memory:

The “Check Transmission” light will continue to repeat the flash code sequence for that fault until you turn the ignition OFF.

4.

If the TCU has stored more than one fault into memory:

The “Check Transmission” light will continue to repeat the flash code sequences for all of the faults until you turn the ignition OFF.

5. After all of the flash codes have been displayed, the “Check Transmission” light will pause for two seconds and then continue to display the flash codes again until you turn the engine OFF. The faults will remain in TCU memory until you clear them.

Figure 2.1

CTL

Flash Code 36: Low Range Solenoid Voltage Fault

PAUSE

3 SEC

3 Flashes

SHORT

PAUSE

6 Flashes

CTL CTL CTL CTL CTL CTL CTL CTL CTLLONGER

PAUSE

NEXT FLASH

CODE DISPLAYED

Flash Code 226: ESSTM Switch Assembly Fault

2 Flashes 2 Flashes 6 Flashes

FLASH CODES

REPEAT UNTIL

YOU TURN THE

IGNITION OFF

= CHECK TRANSMISSION LIGHT ON

Example: Flash Codes 36 and 226

SHORT

PAUSESHORT

PAUSE

LONGER

PAUSE

CTL CTL CTL CTL CTL CTL CTL CTL CTL CTL

CTL


9

Record the Flash Codes

1. Prepare to write down the flash code sequences that the “Check Transmission” light will display when you turn the ignition ON.

2. After you record the flash codes, turn the ignition OFF.

How to Read Flash Codes

1. Compare each two- or three-digit flash code sequence that you have recorded to the fault that corresponds in the table below.

2. Test each area where the “Check Transmission” light has identified a fault. Repair the fault. Clear the flash codes from TCU memory.

Flash Codes and Fault Descriptions

Flash Codes Flash Code Descriptions

194 No codes

231 J-1939 communications link fault

254 Controller fault

251 Low voltage fault: Voltage below normal or shorted low

226 Neutral/in gear switch

227 Shift knob fault: Data erratic, intermittent or incorrect

227 Shift knob fault: Voltage above normal or shorted high

227 Shift knob fault: Voltage below normal or shorted low

35 High range solenoid: Voltage above normal or shorted high

35 High range solenoid: Voltage below normal or shorted low

36 Low range solenoid: Voltage above normal or shorted high

36 Low range solenoid: Voltage below normal or shorted low

191 Vehicle speed sensor fault: Data erratic, intermittent or incorrect

191 Vehicle speed sensor fault: Voltage above normal or shorted high

191 Vehicle speed sensor fault: Voltage below normal or shorted low

191 Vehicle speed sensor fault: Abnormal frequency, pulse width or period (invalid gear)

151 Stuck in gear fault

124 Transmission oil level sensor: Data valid but above normal operational range

124 Transmission oil level sensor: Data erratic, intermittent or incorrect

177 Transmission temperature sensor: Voltage above normal or shorted high

177 Transmission temperature sensor: Data erratic, intermittent or incorrect


10

How to Clear Flash Codes from TCU Memory

NOTE:

The vehicle must be stationary to retrieve flash codes. Have a ZF Meritor-authorized technician repair all active faults before clearing flash codes.

1. Park the vehicle. Turn the engine OFF. Turn the ignition ON. The check transmission light must be displaying flash codes before you can clear the codes from TCU memory.

2. PRESS and HOLD the diagnostic toggle switch.

3. Turn the ignition OFF. Continue to hold the diagnostic toggle switch for about three seconds.

4. Release the diagnostic toggle switch. The flash codes will be cleared from TCU memory.

Testing ESS

TM

System Conditions That Do Not Have Flash Codes(NO ACTIVE CODE)

ZF Meritor’s Engine Synchro Shift

TM

(ESS

TM

) transmission electronic control module (ECM) uses sequences of light flashes called flash codes to identify and display faults that the ECM detects and stores into memory. Each fault that is related to the ESS

TM

transmission has its own flash code sequence.

However, three conditions can occur that are not ESS

TM

system-related faults and, therefore, do not have flash codes (NO ACTIVE CODE): The two neutral/in gear switch circuits short and remain open, the cruise control pause switch short and remain open, the cruise control pause switch shorts and remains open, and the OEM clutch switch assembly does not operate correctly. Refer to the table below for results of, and corrective actions for, these conditions.

Conditions Results Corrective Actions

The two neutral/in gear switch circuits short and remain

OPEN

.

•

The ECM deactivates the ESS

TM

system.

•

The transmission will not complete ESS

TM

shifts or automatic range shifts, even if the ESS

TM

system switch is in the ON position.

•

The ESS

TM

shift intent switch is deactivated, and the transmission will not complete manual range shifts.

•

The transmission will operate under manual control.

Use a volt-ohm meter (VOM) to test the neutral/in gear switch to verify that the switch operates correctly.Replace as necessary.

The OEM clutch switch assembly does not operate correctly.

•


TM

system.

•

The transmission will not complete an ESS

TM

shift.

•


Contact the original equipment manufacturer (OEM) for procedures on how to test the clutch switch assembly.

The cruise control pause switch shorts and remains

OPEN

.

•


TM

system when cruise control is ON.

•

ESS

TM

functions properly when cruise control is OFF.

•


Verify that the cruise control pause switch does not operate correctly. Refer to Service Parts Instructions publication TP-9621,

Shift-n-Cruise™ Tester 3256-B-1068 Instructions.

Replace the cruise control pause switch if necessary. Refer to Transmission Bulletin No. 24 (publication TP-95187),

Shift-n-Cruise™ Connector Instructions

.

For Shift-n-Cruise

TM

, use the Shift-n-Cruise

TM

tester, part number 3256-B-1068, to determine if the pause switch has shorted and remains OPEN.


11

WARNING

To prevent serious eye injury, always wear safe eye protection when you perform maintenance or service.


Wire Splicing Procedure

1. Remove 0.5-inch (12 mm) of insulation from each end of the wires that are to be connected.

Figure 2.2

.

CAUTION

Splices that are not sealed correctly can damage components. Always use the correct crimping tool required for the application to ensure that the splice connector tube will completely seal the wires.

2. Insert each end of the wire(s) into a self-sealing “butt splice” connector tube. Use the correct crimping tool to crimp each end of the tube.

Figure 2.3

.

WARNING

If used incorrectly, a heat gun can cause serious personal injury and damage to components. Always carefully follow the manufacturer’s instructions when you use a heat gun.

3. Use a heat gun to heat the connector until the ends of the connector seal the wire. Carefully follow the manufacturer’s instructions when you use the heat gun.

Figure 2.4

.

4. Pull the connector to verify that it is crimped correctly.

WARNING

Wire splices that are placed too close together can “short circuit” and cause serious personal injury and damage to components. Always position wire splices at least one inch (25 mm) apart.

5. Position wire splices at least one inch (25 mm) apart.

Figure 2.5

.

Figure 2.2

Figure 2.3

Figure 2.4

Figure 2.5

Remove 1/2-inch (12 mm)of insulation.

Heat untilends of connector

seal the wires.

Position wire splices at least one inch (25 mm) apart.


12

Apply Dielectric Grease to Range Solenoid Pin Connectors

To help prevent corrosion, ZF Meritor recommends that you apply dielectric grease to range solenoid pin connectors on ESS

TM

transmissions.

Figures

2.6

and

2.7

.

Required Tools

r

Torque wrench — lb-in

r

Torque wrench — lb-ft

r

Standard Allen wrench set

r

Small flat-blade screwdriver (pocket)

r

Side cutter (wire cutter)

r

Standard Phillips head screwdriver

r

Gasket scraper

r

Needlenose pliers

r

Standard combination wrench set (3/8-inch – 1-1/2-inch)

r

Standard 3/8-inch drive socket set (3/8-inch – 1-1/2-inch)

r

Standard ratchet

r Air ratchet (optional)

r Digital volt-ohm meter (VOM)

Figure 2.6

Figure 2.7

Apply dielectricgrease here.

Applydielectricgrease here.

RANGECYLINDERSOLENOIDS

DIELECTRIC GREASE

Section 2VOM Diagnostics

Shift Knob Test

13

VOM DiagnosticsShift Knob TestNOTE: If erratic readings occur when you perform electrical circuit tests, verify that the connections are tight and the terminals are clean. Retest the circuit.

Disconnect the thirty-pin TCU connector from the transmission harness.

r GO TO THE NEXT STEP.

Check the resistance between TCU connector sockets J3 and K2 (shift knob circuit). Refer to the table above for the appropriate resistance specification.

Is the resistance within specification?

r YES R GO TO STEP 9.

r NO R GO TO THE NEXT STEP.

Step 1

WIRING HARNESS

30-PIN TCU CONNECTOR

Step 2

System Shift Intent Switch Resistance

ON FULL UP 42.3–44.1 k ohmsON UP 57.0–59.4 k ohmsON DOWN 24.5–25.5 k ohmsON FULL DOWN 9.8–10.2 k ohmsOFF UP 123.8–128.8 k ohmsOFF DOWN 91.2–95.0 k ohms

ABCDE

FGHJK

1 2 3

PAUSERESUME

SET

OHMS

SHIFTINTENTSWITCH

SYSTEMSWITCH

Remove the Phillips head screw that attaches the shift knob skirt to the shift knob housing.


Separate the shift knob skirt from the shift knob assembly to expose the electrical connectors.


Step 3

SHIFTKNOB

#2 PHILLIPSHEAD SCREWDRIVER

SKIRT

Step 4

SHIFTKNOB

SKIRT

14

Section 2VOM DiagnosticsShift Knob Test

Disconnect the two-pin shift knob wiring harness connector.


Check resistance between shift knob wiring harness connector sockets A and B. The key is OFF for all RESISTANCE tests. Refer to the wiring diagram for pin assignments.

Refer to the table above. Is the resistance within specification?

r YES R CONNECT THE SHIFT KNOB. REPLACE THE WIRING HARNESS. (REFER TO SECTION 5.)

r NO R REPLACE THE SHIFT KNOB. (REFER TO SECTION 5.)

Step 5

PAUSERESUME

SET

SHIFTKNOB

SHIFT KNOB WIRINGHARNESSCONNECTOR

Step 6


ON FULL UP 42.3–44.1 k ohms

ON UP 57.0–59.4 k ohms

ON DOWN 24.5–25.5 k ohms

ON FULL DOWN 9.8–10.2 k ohms

OFF UP 123.8–128.8 k ohms

OFF DOWN 91.2–95.0 k ohms

A B

OHMS

SHIFTKNOB HARNESS

Connect the electrical connectors at the base of the shift knob. Push the connectors together until the tabs are engaged.


Replace the shift knob skirt. Replace and tighten the Phillips head screw.


Step 7

SHIFTKNOB

PAUSERESUME

SET

Step 8

SHIFTKNOB


SHIFTKNOBSKIRT


Shift Knob Test

15

Connect the thirty-pin TCU connector.

Step 9

WIRING HARNESS


16

Section 2VOM DiagnosticsShift Solenoid Test

NOTE: If erratic readings occur when you perform electrical circuit tests, verify that the connections are tight and the terminals are clean. Retest the circuit.

Disconnect the thirty-pin TCU connector from the transmission wiring harness.


Check the resistance between TCU connector sockets A1 and B2 (high range solenoid circuit).

Is the resistance 11-12 ohms?

r YES R HIGH RANGE SOLENOID IS OKAY. GO TO STEP 6.


Step 1

WIRING HARNESS


Step 2

ABCDE

FGHJK

1 2 3

OHMS

Disconnect the two-pin HIGH range solenoid connector.

r GO TO THE NEXT STEP.Shift Solenoid Test

Step 3

HIGH RANGESOLENOID

LOW RANGESOLENOID


17

Check the resistance at the HIGH range solenoid pins. The key is OFF for all resistance tests.


r YES R REPLACE THE WIRING HARNESS.(REFER TO SECTION 5.)

r NO R REPLACE THE HIGH RANGE SOLENOID. (REFER TO SECTION 5.)

NOTE: A diode can cause a solenoid to test at zero ohms, even when a solenoid is in good condition. If the solenoid tests at zero, switch the volt-ohm meter (VOM) leads and check for the following conditions:

r Closed circuit zero ohms one way

r 11-22 ohms with VOM leads switched

Step 4

HIGH RANGE SOLENOID

OHMS

Connect the two-pin HIGH range solenoid connector.


Check the resistance between TCU connector sockets A1 and B1 (LOW range solenoid circuit).


r YES R LOW RANGE SOLENOID IS OKAY. GO TO STEP 10.


Step 5

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 6

ABCDE

FGHJK

1 2 3

OHMS

18


Disconnect the two-pin LOW range solenoid connector.


Check the resistance at the LOW range solenoid pins. The key is OFF for all resistance tests.



r NO R REPLACE THE LOW RANGE SOLENOID.(REFER TO SECTION 5.)

Step 7

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 8

HIGH RANGE SOLENOID

LOW SOLENOID

OHMS

Connect the two-pin LOW range solenoid connector.



Step 9

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 10

WIRING HARNESS



Switch Assembly Test

19

Switch Assembly TestNOTE: If erratic readings occur when you perform electrical circuit tests, verify that the connections are tight and the terminals are clean. Retest the circuit.

Disconnect the thirty-pin transmission wiring harness to TCU.


Put the transmission into NEUTRAL.


Step 1

WIRING HARNESS


Step 2

PAUSE RESUME

SET

Check the resistance between TCU connector sockets A3 and G1 (ESSTM NEUTRAL switch circuit). The key is OFF for all resistance tests.

Is the resistance at or below 0.5 ohms?



Disconnect the four-pin NEUTRAL position switch harness connector.


Step 3

ABCDE

FGHJK

1 2 3

OHMS

Step 4

NEUTRAL POSITIONSWITCH CONNECTOR

20

Section 2VOM DiagnosticsSwitch Assembly Test

Check the resistance between NEUTRAL position switch wiring harness connector sockets A and B.




Remove the top cover. (Refer to Section 5.)


Step 5

A B C D

OHMS

Step 6

TOPCOVER

Remove and inspect the NEUTRAL check shaft and spring. (Refer to Section 5.)

Is there damage?

r YES R REPLACE DAMAGED TOP COVER COMPONENTS. CHECK THE SYSTEM FOR CORRECT OPERATION.

r NO R REPLACE THE SWITCH ASSEMBLY. (REFER TO SECTION 5.) GO TO THE NEXT STEP.

Install the top cover. (Refer to Section 5.)


Step 7

NEUTRAL CHECK SHAFT

NEUTRAL CHECKSHAFT SPRING

Step 8

TOPCOVER



21

Connect the four-pin switch assembly connector.


Put the transmission into gear.


Step 9


Step 10

PAUSE RESUME

SET

Check the resistance between TCU connector sockets A3 and G2 (ESSTM in gear switch circuit). The key is OFF for all resistance tests.




Disconnect the four-pin switch assembly.


Step 11

ABCDE

FGHJK

1 2 3

OHMS

Step 12


22

Section 2VOM DiagnosticsSwitch Assembly Test

Check the resistance between in gear switch wiring harness connector sockets C and D.


r YES R REPLACE THE WIRING HARNESS. (REFER TO SECTION 5.)




Step 13

A B C D

OHMS

Step 14

TOPCOVER


Is there damage?





Step 15

NEUTRAL CHECK SHAFT


Step 16

TOPCOVER



23




Step 17


Step 18

WIRING HARNESS


24

Section 2VOM DiagnosticsVehicle Speed Sensor Test

Vehicle Speed Sensor TestNOTE: If erratic readings occur when you perform electrical circuit tests, verify that the connections are tight and the terminals are clean. Retest the circuit.



Check the resistance between TCU connector sockets A3 and B3 (vehicle speed sensor circuit). The key is OFF for all RESISTANCE tests.

Is the resistance 2.7k-3.3k ohms?



Step 1

WIRING HARNESS


Step 2

ABCDE

FGHJK

1 2 3

OHMS

Disconnect the two-pin vehicle speed sensor connector from the wiring harness.


Check resistance across VSS pins. The key is OFF for all RESISTANCE tests. Refer to the wiring diagram for pin assignments.

Is resistance 2.7k-3.3k ohms?


r NO R REPLACE THE VEHICLE SPEED SENSOR. (REFER TO SECTION 5.)

Step 3

VSS

Step 4

OHMS


Vehicle Speed Sensor Test

25

Connect the two-pin vehicle speed sensor connector.



Step 5

VSS

Step 6

WIRING HARNESS


26

Section 2

VOM Diagnostics

Wiring Harness Test

Section 21VOM DiagnosticsWiring Harness Test

NOTE:

If erratic readings occur when you perform electrical circuit tests, verify that the connections are tight and the terminals are clean. Retest the circuit.


r

GO TO THE NEXT STEP.

Check the resistance between TCU connector sockets J3 and K2 (shift knob circuit). Refer to the chart for the appropriate resistance specification.


r

YES

R

GO TO STEP 9.

r

NO

R


Step 1

WIRING HARNESS


Step 2


ON FULL UP

42.3–44.1 k ohms

ON UP

57.0–59.4 k ohms

ON DOWN

24.5–25.5 k ohms

ON FULL DOWN

9.8–10.2 k ohms

OFF UP

123.8–128.8 k ohms

OFF DOWN

91.2–95.0 k ohms

ABCDE

FGHJK

1 2 3

PAUSERESUME

SET

OHMS

SHIFTINTENTSWITCH

SYSTEMSWITCH

NOTE:

If erratic readings occur when you perform electrical circuit tests, verify that the connections are tight and the terminals are clean. Retest the circuit.

Remove the Phillips head screw that attaches the shift knob skirt to the shift knob housing.

r


Separate the shift knob skirt from the shift knob assembly to expose the electrical connectors.

r


Step 3

SHIFTKNOB


SKIRT

Step 4

SHIFTKNOB

SKIRT

Section 2

VOM Diagnostics

Wiring Harness Test

27

Disconnect the two-pin shift knob wiring harness connector.

r


Check resistance between shift knob wiring harness connector sockets A and B. The key is OFF for all RESISTANCE tests. Refer to the wiring diagram for pin assignments.


r

YES

R

CONNECT THE SHIFT KNOB. REPLACE THE WIRING HARNESS. (REFER TO SECTION 5.)

r

NO

R

REPLACE THE SHIFT KNOB. (REFER TO SECTION 5.)

Step 5

PAUSERESUME

SET

SHIFTKNOB

SHIFT KNOB WIRINGHARNESSCONNECTOR

Step 6


ON FULL UP

42.3–44.1 k ohms

ON UP

57.0–59.4 k ohms

ON DOWN

24.5–25.5 k ohms

ON FULL DOWN

9.8–10.2 k ohms

OFF UP

123.8–128.8 k ohms

OFF DOWN

91.2–95.0 k ohms

A B

OHMS

SHIFTKNOB HARNESS

Connect the electrical connectors at the base of the shift knob. Push the connectors together until the tabs are engaged.

r


Replace the shift knob skirt. Replace and tighten the Phillips head screw.

r


Step 7

SHIFTKNOB

PAUSERESUME

SET

Step 8

SHIFTKNOB


SHIFTKNOBSKIRT

28

Section 2

VOM Diagnostics

Wiring Harness Test

Check the resistance between TCU connector sockets A1 and B2 (HIGH range solenoid circuit).


r

YES

R

HIGH RANGE SOLENOID IS OKAY. GO TO STEP 13.

r

NO

R


Disconnect the two-pin HIGH range solenoid connector.

r


Step 9

ABCDE

FGHJK

1 2 3

OHMS

Step 10

HIGH RANGESOLENOID

LOW RANGESOLENOID

Check the resistance at the HIGH range solenoid pins. The key is OFF for all resistance tests.


r

YES

R

REPLACE THE WIRING HARNESS. (REFER TO SECTION 5.)

r

NO

R

REPLACE THE HIGH RANGE SOLENOID. (REFER TO SECTION 5.)

NOTE:

A diode can cause a solenoid to test at zero ohms, even when a solenoid is in good condition. If the solenoid tests at zero, switch the volt-ohm meter (VOM) leads and check for the following conditions:

r

Closed circuit zero ohms one way

r

11-22 ohms with VOM leads switched

Step 11

HIGH RANGE SOLENOID

OHMS

Section 2

VOM Diagnostics

Wiring Harness Test

29

Connect the two-pin HIGH range solenoid connector.

r


Check the resistance between TCU connector sockets A1 and B1 (LOW range solenoid circuit).


r

YES

R

LOW RANGE SOLENOID IS OKAY. GO TO STEP 17.

r

NO

R


Step 12

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 13

ABCDE

FGHJK

1 2 3

OHMS

Disconnect the two-pin LOW range solenoid connector.

r


Check the resistance at the LOW range solenoid pins. The key is OFF for all resistance tests.


r

YES

R

REPLACE THE WIRING HARNESS. (REFER TO SECTION 5.)

r

NO

R

REPLACE THE LOW RANGE SOLENOID. (REFER TO SECTION 5.)

Step 14

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 15

HIGH RANGE SOLENOID

LOW SOLENOID

OHMS

30

Section 2

VOM Diagnostics

Wiring Harness Test

Connect the two-pin LOW range solenoid connector.

r


Put the transmission into NEUTRAL.

r


Step 16

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 17

PAUSE RESUME

SET

Check the resistance between TCU connector sockets A3 and G1 (NEUTRAL switch circuit). The key is OFF for all resistance tests.


r

YES

R

GO TO STEP 25.

r

NO

R


Disconnect the four-pin NEUTRAL position switch wiring harness connector.

r


Step 18

ABCDE

FGHJK

1 2 3

OHMS

Step 19



31

Check the resistance between NEUTRAL position switch wiring harness connector sockets A and B.






Step 20

A B C D

OHMS

Step 21

TOPCOVER


Is there damage?





Step 22

NEUTRAL CHECK SHAFT


Step 23TOPCOVER

32




Place the transmission into gear.


Step 24


Step 25

PAUSE RESUME

SET

Check the resistance between TCU connector sockets A3 and G2 (in gear switch circuit). The key is OFF for all resistance tests.




Disconnect the four-pin switch assembly.


Step 26

ABCDE

FGHJK

1 2 3

OHMS

Step 27



33

Check the resistance between NEUTRAL position switch wiring harness connector sockets C and D.






Step 28

A B C D

OHMS

Step 29TOPCOVER


Is there damage?





Step 30

NEUTRAL CHECK SHAFT


Step 31TOPCOVER

34


Connect the four-pin NEUTRAL position switch assembly connector.


Check the resistance between TCU connector sockets A3 and B3 (vehicle speed sensor circuit). The key is OFF for all resistance tests.

Is the resistance 2.7k-3.3k ohms?



Step 32


Step 33

ABCDE

FGHJK

1 2 3

OHMS

Disconnect the two-pin vehicle speed sensor connector from the wiring harness.


Check resistance across VSS pins. The key is OFF for all resistance tests. Refer to the wiring diagram for pin assignments.

Is resistance 2.7k-3.3k ohms?


r NO R REPLACE THE VEHICLE SPEED SENSOR. (REFER TO SECTION 5.)

Step 34

VSS

Step 35

OHMS


35

Connect the two-pin vehicle speed sensor connector.


Disconnect the two-pin J-1708 connector.


Step 36

VSS

Step 37

J-1708

Check continuity between wiring harness sockets E1 (TCU connector) and B (J-1708 connector).

Is there continuity?

r YES R GO TO THE NEXT STEP.

r NO R REPLACE THE WIRING HARNESS. (REFER TO SECTION 5.)

Check continuity between wiring harness sockets E2 (TCU connector) and A (J-1708 connector).




Step 38

ABCDE

FGHJK

1 2 3

OHMS

B A

Step 39

ABCDE

FGHJK

1 2 3

OHMS

B A

36


Connect the two-pin J-1708 connector.


Disconnect the three-pin J-1939 connector.


Step 40

J-1708

Step 41

J-1939

Check continuity between wiring harness sockets D3 (TCU connector) and C (J-1939 connector).




Check continuity between wiring harness sockets D2 (TCU connector) and B (J-1939 connector).




Step 42

AB

C

ABCDE

FGHJK

1 2 3

OHMS

Step 43

AB

C

ABCDE

FGHJK

1 2 3

OHMS


37

Check continuity between wiring harness sockets D1 (TCU connector) and A (J-1939 connector).




Connect the three-pin J-1939 connector.


Step 44

AB

C

ABCDE

FGHJK

1 2 3

OHMS

Step 45

J-1939

Disconnect the six-pin OEM power connector.


Check continuity between wiring harness sockets A1 (TCU connector) and B (OEM connector).




Step 46

OEM

Step 47

ABCDE

FGHJK

1 2 3

OHMS

CB

A

A

B

C

F

E

D

38


Check continuity between wiring harness sockets A2 (TCU connector) and E (OEM connector).




Check continuity between wiring harness sockets A3 (TCU connector) and D (OEM connector).




Step 48

ABCDE

FGHJK

1 2 3

OHMS

CB

A

A

B

C

F

E

D

Step 49

ABCDE

FGHJK

1 2 3

OHMS

CB

A

A

B

C

F

E

D

Check continuity between wiring harness sockets E3 (TCU connector) and A (OEM connector).




Connect the six-pin OEM connector.


Step 50

A

B

C

F

E

D

ABCDE

FGHJK

1 2 3

OHMS

CB

A

Step 51

OEM


39


Step 52

WIRING HARNESS


Section 2

VOM Diagnostics

Shift Solenoid Test

40

Section 2Section 2

Sh

ift

So

len

oid

Test

Fla

sh

Co

des 3

5 a

nd

36

Dis

con

nec

tth

eth

irty

-pin

TC

U w

irin

gh

arn

ess

Mea

sure

th

ere

sist

ance

bet

wee

nA

1 an

d B

2

11-2

2o

hm

s?

YE

S

NO

Dis

con

nec

tth

e tw

o-p

inH

IGH

ran

ge

sole

no

idco

nn

ecto

r

Mea

sure

th

ere

sist

ance

acro

ss t

he

HIG

H r

ang

eso

len

oid

11-2

2o

hm

s?

YE

S

NO

Rep

lace

the

HIG

H

ran

ge

sole

no

id

Co

nn

ect

the

two

-pin

HIG

H r

ang

eso

len

oid

con

nec

tor

Rep

lace

the

wir

ing

har

nes

sM

easu

re t

he

resi

stan

ceb

etw

een

A1

and

B1

11-2

2o

hm

s?

YE

S

NO

Dis

con

nec

tth

e tw

o-p

inLO

W r

ang

eso

len

oid

con

nec

tor

Mea

sure

th

ere

sist

ance

acro

ss t

he

LO

W r

ang

eso

len

oid

11-2

2o

hm

s?

YE

S

NO

Rep

lace

the

LO

W

ran

ge

sole

no

id

Co

nn

ect

the

two

-pin

LO

W r

ang

eso

len

oid

con

nec

tor

Rep

lace

the

wir

ing

har

nes

sC

on

nec

t th

eth

irty

-pin

TC

Uco

nn

ecto

r

Section 2

VOM Diagnostics

Vehicle Speed Sensor Test

41

VOM DiagnosticsVehicle Speed Sensor Test

Veh

icle

Sp

eed

Sen

so

r T

est

Fla

sh

Co

de 1

91

Dis

con

nec

tth

e th

irty

-pin

TC

Uh

arn

ess

2.7k

-3.3

ko

hm

s?

YE

S

NO

YE

S

Mea

sure

th

ere

sist

ance

acro

ss p

ins

A3

and

B3

Co

nn

ect

the

thir

ty-p

inT

CU

con

nec

tor

Dis

con

nec

tth

e tw

o-p

inV

ehic

le S

pee

dS

enso

rco

nn

ecto

r

Mea

sure

the

resi

stan

ceac

ross

th

eV

SS

cir

cuit

2.7k

-3.3

ko

hm

s?R

epla

ceth

e V

SS

Co

nn

ect

the

two

-pin

VS

Sco

nn

ecto

r

Rep

lace

the

wir

ing

har

nes

s

NO

Section 2

VOM Diagnostics


42

VOM DiagnosticsSwitch Assembly Test

Sw

itch

Assem

bly

Test

Fla

sh

Co

de 2

26

Mea

sure

th

ere

sist

ance

bet

wee

nA

3 an

d G

1

Pla

ce t

he

tran

smis

sio

nin

to

NE

UT

RA

L

0.0-

0.5

oh

ms?

YE

S

NO

YE

S

NO

Dis

con

nec

tth

e th

irty

-pin

TC

Uco

nn

ecto

r

Mea

sure

th

ere

sist

ance

bet

wee

nA

3 an

d G

2

Pla

ce t

he

tran

smis

sio

nin

to g

ear

0.0-

0.5

oh

ms?

YE

S

Co

nn

ect

the

thir

ty-p

inT

CU

con

nec

tor

Dis

con

nec

tth

esw

itch

asse

mb

ly

Mea

sure

th

ere

sist

ance

bet

wee

n p

ins

A a

nd

B

Rem

ove

the

top

cove

r

0.0-

0.5

oh

ms?

Ch

eck

for

dam

age

to t

he

neu

tral

sp

rin

gan

d s

haf

t

YE

S

NO

Isth

ere

dam

age?

Rep

lace

the

swit

chas

sem

bly

Inst

all

the

top

cove

r

Co

nn

ect

the

fou

r-p

in

swit

chas

sem

bly

Rep

lace

the

dam

aged

top

co

ver

com

po

nen

ts

Rep

lace

the

wir

ing

har

nes

s

NO

YE

S

NO

Dis

con

nec

tth

esw

itch

asse

mb

ly

Mea

sure

th

ere

sist

ance

bet

wee

n p

ins

C a

nd

D

Rem

ove

the

top

cove

r

0.0-

0.5

oh

ms?

Ch

eck

for

dam

age

to t

he

neu

tral

sp

rin

gan

d s

haf

t

YE

S

NO

Isth

ere

dam

age?

Rep

lace

the

swit

chas

sem

bly

Inst

all

the

top

cove

r

Co

nn

ect

the

fou

r-p

insw

itch

asse

mb

ly

Rep

lace

the

dam

aged

top

co

ver

com

po

nen

ts

Rep

lace

the

wir

ing

har

nes

s

Section 2

VOM Diagnostics

Shift Knob Test

43

Shift Knob Test

Sh

ift

Kn

ob

Test

Fla

sh

Co

de 2

27

Dis

con

nec

tth

eth

irty

-pin

TC

Uh

arn

ess

Mea

sure

th

ere

sist

ance

acro

ss p

ins

J3 a

nd

K2

In s

pec

?R

efer

to

Tab

le 1

YE

S

NO

Rem

ove

the

shif

tkn

ob

ski

rtre

tain

ing

scre

w

Mo

ve t

he

shif

tkn

ob

ski

rtd

ow

n a

nd

away

fro

m t

he

con

nec

tors

In s

pec

?R

efer

to

Tab

le 1

NO

YE

S

Rep

lace

the

wir

ing

har

nes

s

Rep

lace

th

esh

ift

kno

bsk

irt

and

tig

hte

n t

he

reta

inin

g s

crew

Rep

lace

the

shif

t kn

ob

Co

nn

ect

the

thir

ty-p

inT

CU

con

nec

tor

Syste

mS

hif

t In

ten

t S

wit

ch

Resis

tan

ce

Dis

con

nec

tth

e tw

o-p

insh

ift

kno

bco

nn

ecto

r

Co

nn

ect

the

two

-pin

sh

ift

kno

bco

nn

ecto

r

ON

FU

LL

UP

42.3

–44.

1 k

oh

ms

ON

UP

57.0

–59.

4 k

oh

ms

ON

D

OW

N24

.5–2

5.5

k o

hm

s

ON

FU

LL

DO

WN

9.8–

10.2

k o

hm

s

OFF

UP

123.

8–12

8.8

k o

hm

s

OFF

DO

WN

91.2

–95.

0 k

oh

ms

Tab

le 1

Mea

sure

th

ere

sist

ance

acro

ss t

he

pin

s. R

efer

to T

able

1

Section 3Pro-Link

®

9000 Diagnostics

44

Section 3Pro-Link

®

9000 Diagnostics

Overview

ESS™ System Diagnostics Using the Pro-Link

®

9000 Diagnostic Data Reader (DDR) with ZF Meritor’s ESS™ PCMCIA Card

Pro-Link

®

9000 is a registered trademark of Micro Processor Systems, Inc. (MPSI).

The Pro-Link

®

9000 diagnostic data reader (DDR) uses ZF Meritor’s ESS

TM

PCMCIA card.

1. Follow the manufacturer’s instructions when you use this tool.

2. Verify that you are using the correct PCMCIA card for the vehicle you will test. Check the PCMCIA card identification tag for the following information:

r

The vehicle systems the cartridge covers

r

The manufacturer’s name and address

r

The PCMCIA card model and serial number

Contact SPX Kent-Moore Heavy Duty Division at 800-328-6657 to order the following items:

r

Pro-Link

®

9000 diagnostic data reader (DDR) (part number J38500-1)

r

Multi-protocol cartridge (MPC) (part number J38500-1500)

r

ZF Meritor’s ESS™ PCMCIA card (part number J38500-4200)

Non-Volatile Memory Cartridge Means No Lost Data

The multi-protocol cartridge (MPC) hasnon-volatile memory, which means that stored data is not lost when you disconnect the Pro-Link

®

9000 DDR from the vehicle’s power source.

When the Pro-Link

®

9000 DDR is connected to an external power source, such as the vehicle’s cigarette lighter, the DDR does not communicate with the vehicle’s transmission control unit (TCU), but the FUNC key is still active. You can use this key to access and retrieve stored data for review and printing.

Stored Data That Is Retrievable

r

TCU operating data

r

Diagnostic codes

r

Calibration data

r

Snapshot data

Readout Window

The readout window contains a liquid crystal display (LCD) that uses letters, numbers and special symbols.

Keypad and Key Functions

Keypad

The 16-character keypad is sealed against contamination from grease and fluids. Clean the keys with a damp cloth.

7 8 9

4 5 6

1 2 3

0 ENTER FUNC

Section 3Pro-Link

®

9000 Diagnostics

45

Ten Numeric Keys

Ten NUMERIC KEYS are arranged calculator-style. Each key is imprinted with a single digit.

Four Arrow Keys

r

The

q

and

Q

keys scroll one line at a time through the display.

r

The

r

and

R

keys move between choices given by the display. Depending on the cartridge you are using, these keys can also be used for other purposes.

Function Key (FUNC)

Use the FUNC key to select several operating modes and a printing mode.

ENTER Key

Use the ENTER key to make a selection, confirm an answer or instruct the Pro-Link

®

9000 DDR to go to the next step.

Installing the Multi-Protocol Cartridge (MPC) Into the Pro-Link

®

9000 DDR

1. Disconnect the 12V vehicle adaptor before you insert the MPC into the Pro-Link

®

9000 DDR.

2. Hold the MPC straight and not at an angle. You can only insert the cartridge one way onto the Pro-Link

®

9000 DDR.

3. Seat the MPC on the back of the Pro-Link

®

9000 DDR. The connector (edgeboard) of the cartridge automatically lines up with the connector in the DDR.

4. Slide the MPC forward until it clicks into place.

Installing the PCMCIA Card Into the MPC

1. Disconnect the 12V vehicle adaptor before you insert the MPC into the Pro-Link

®

9000 DDR. Securely hold the MPC and the DDR.

2. Insert the PCMCIA card into the MPC so that the arrows are visible and face

TOWARD

the MPC.

Figure 3.1

.

3. Slide the PCMCIA card

FORWARD

until it seats firmly.

Removing the PCMCIA Card

1. Press the EJECT button on the side of the PCMCIA card.

Figure 3.1

.

2. Carefully remove the PCMCIA card.

Display Data Line (DDL) Cable Connection

The Pro-Link

®

9000 DDR receives information from the TCU through a connector called the display data line (DDL) cable.

Connect the Pro-Link

®

9000 DDL Adaptor Plug to the DDL Cable

NOTE:

The Pro-Link

®

9000 DDL adaptor plug installs into the DDL cable one way only.

The Pro-Link

®

9000 DDL CABLE has fifteen wires, a molded connector with fifteen pin sockets and does not connect directly to the DDL CONNECTOR in the vehicle.

1. Connect the DDL cable to the Pro-Link

®

9000 DDR.

2. Connect the DDL adaptor plug onto the DDL CABLE. (The adaptor plug has fifteen pins on one side, with the other side customized for a specific application.)

3. Plug the adaptor into the DDL connector in the vehicle.

4. Turn the vehicle’s ignition ON. The engine does not have to be running. The Pro-Link

®

9000 DDR will power up as soon as you plug the DDL adaptor plug into the DDL connector.

Figure 3.1

Section 3Pro-Link

®

9000 Diagnostics

46

What to Check if the Pro-Link

®

9000 DDR Does Not Power Up

The Pro-Link

®

9000 DDR will power up as soon as you connect it to the vehicle’s electrical system. If the DDR does not power up, check the following:

1. Check that the ignition is ON.

2. Check that the MPC is connected to the DDR correctly: Slide the MPC out of the DDR and plug it into the DDR again.

3. Check that the PCMCIA card is connected to the MPC correctly: Remove and insert the PCMCIA Card.

4. Check the edgeboard for grease, oil or other contaminants. Use a soft cloth to carefully clean the edgeboard, if necessary. Do not use solvents to clean the edgeboard.

System Selection

System Selection Process

The Pro-Link

®

9000 DDR communicates with the TCU to automatically determine which ESS™ system you are testing. The screen display will ask you to wait while this process is taking place.

Copyright Screen

When the Pro-Link

®

9000 DDR powers up, the readout displays the copyright screen for several seconds, followed by the Data List screen.

Data Display

Data Readout

r

If the Pro-Link

®

9000 DDR cannot communicate with the TCU, the DDR displays the NO DATA screen:

r

Press the ENTER key to try again to connect with the TCU.

r

If the Pro-Link

®

9000 DDR still cannot communicate with the TCU and the NO DATA screen disappears, refer to “Installing the PCMCIA Card Into the MPC” and “Connect the Pro-Link

®

9000 DDL Adaptor Plug to the DDL Cable” in this section.

Recall Data

The MPC records and stores data from the last vehicle that you serviced. You can retrieve all stored data (such as Snapshot, etc.).

Press the FUNC key to recall data from memory. Refer to “How to Retrieve Data Stored in the Pro-Link

®

9000 DDR Without Using the Vehicle’s DDL” in this section for instructions on how to access the Data List.

NO DATA Readout

If the NO DATA readout displays on the screen:

1. Check the vehicle cable at each terminal to verify that the connections are good. A broken wire in the vehicle cable or in the TCU can cause a faulty connection, and the system will display a NO DATA readout.

2. Check that the ignition key is turned ON. Whenthe ignition is OFF, the system will display aNO DATA readout.

M P C B o o t v 1 . 0C O P Y R I G H T

1 9 9 6 W P I M P S I

N O E S S DATAR E C E I V E D

E N T E R T O R E T R YF U N C T O R E C A L L DATA

Section 3Pro-Link

®

9000 Diagnostics

47

“Data Freeze” Function

You can view several operating parameters simultaneously (even though the parameters do not appear together on the Data List) by creating a custom Data List or by using the Data Freeze function. Refer to “To ‘Freeze’ a Line of Data” below for instructions on how to create a custom Data List.

r

When you freeze a line of data using the “Data Freeze” function, you will not be able to scroll Data List items that you “freeze.” However, you can scroll the rest of the list.

r

You cannot use “Data Freeze” with “Snapshot.”

To Freeze a Line of Data

NOTE:

A black square next to a line of data indicates that a line is frozen.

1. You must display the Data List on the screen before you can freeze a line of data. The lines in the display are numbered 1 through 4.

2. Use the

q

and

Q

keys to scroll the Data List.

3. Press the numerical key that corresponds to the line number where the item you want to freeze is located. A black square will appear next to that line to indicate that the line is frozen.

4. The following screen indicates that you have decided to freeze AXLE RATIO:

r

You have pressed numerical key 3, because AXLE RATIO data is displayed on LINE 3.

r

A black square appears next to LINE 3 to indicate that this line is frozen.

Scrolling the Data List When You Have Frozen a Line of Data

After you freeze a line of data, you can use the

q

and

Q

keys to scroll the Data List.

In the screen below, LINE 3 is still frozen, but because you have scrolled the Data List, the value has changed from your previous choice, AXLE RATIO on LINE 3, to ENGINE RPM on LINE 3:

Selecting Another Line to Freeze

The following screen indicates that you also have decided to freeze IN GEAR SW on LINE 4:

1. Use the

q

and

Q

keys to scroll the Data List. You will notice that your previous selection, LINE 3, remains frozen.

2. Scroll the Data List until IN GEAR SW appears on LINE 4. Press numerical key 4.

3. A black square appears next to LINE 4 to indicate that this line is frozen.

4. Use this procedure until you have frozen data on all four lines.

To Unfreeze One Line of Data

Press the numerical key that corresponds to the line of data you want to unfreeze. The black square will disappear, which indicates that you have unfrozen the line. The line will now scroll when you use the

q and Q keys.

To Unfreeze All Lines at Once

Press the “0” numerical key. All black squares will disappear to indicate that you have unfrozen all of the lines.

A C T I V E C O D E S N O I N A C T I V E C O D E S N O A X L E R AT I O 2 . 8 0 L O W S O L E N O I D O N

E S S E N A B L E O N N E U T R A L S W O N E N G I N E R P M 1 2 3 4 I N G E A R S W O F F

E S S E N A B L E O N N E U T R A L S W O N E N G I N E R P M 1 2 3 4 I N G E A R S W O F F

Section 3Pro-Link® 9000 Diagnostics

48

How to Retrieve Data Stored in the Pro-Link® 9000 DDR Without Using the Vehicle’s DDL

The Pro-Link® 9000 DDR enables you to retrieve stored data after you remove the DDL adaptor plug from the DDL connector. You can only retrieve data that is stored from the previous vehicle.

1. Install the DDEC II and III cartridge onto the Pro-Link® 9000 DDR.

2. Secure the DDL cable to the Pro-Link® 9000 DDR.

3. Secure the DDL cable to the vehicle’s DDL connector (power cable).

4. Plug the DDL cable into the vehicle’s power outlet (cigarette lighter).

5. The MPSI COPYRIGHT screen will appear, followed by the NO DDEC DATA screen:

6. Press the FUNC key to display the Data List.

How to Open the ESS™ System Application

Install the MPC Application Card

Install the ESS application MPC card into the Pro-Link® 9000 diagnostic data reader (DDR). Refer to “Installing the PCMCIA into the MPC” in this section.

Connect the Pro-Link® 9000 DDR to the Vehicle’s Diagnostic Data Line (DDL) Cable

Connect the Pro-Link® 9000 DDR to the vehicle’s diagnostic data line (DDL). Refer to “Connect the Pro-Link 9000® DDL Adaptor Plug to the DDL Cable” in this section.

When the Pro-Link® 9000 DDR powers up, it displays the COPYRIGHT screen for several seconds:

After the DDR connects to ZF Meritor’s transmission control unit (TCU), the DDR displays the MPSI PRO-LINK MPC screen:

1. Use the q and Q keys to select ZF MERITOR ESS.

2. Press the ENTER key. The DDR displays the FAULT CODES screen:

M P C B o o t v 1 . 0C O P Y R I G H T

1 9 9 6 W P I M P S I

N O E S S DATAR E C E I V E D

E N T E R T O R E T R YF U N C T O R E C A L L DATA

M P C B O O T V 1 . 0C O P Y R I G H T

1 9 9 8 W P I M P S IK K K K K K K

M P S I P R O - L I N K M P CV E R S I O N 2 . 0 0

q- - - - S e l e c t i o n s - - - - QZ F M E R I T O R E S S

Z F M E R I T O R E S S

q- - - - S e l e c t i o n s - - - - QF A U L T C O D E S


49

“ZF Meritor ESS” Menu Options

Ten options are available in the ZF MERITOR ESS menu. Refer to the glossary at the end of this section for a complete description of the options.

Table A: “ZF Meritor ESS” Menu Descriptions

How to Access “ZF Meritor ESS” Menu Options

“Fault Codes” Option

1. Use the q and Q keys to select FAULT CODES from the ZF MERITOR ESS menu.

2. Press the ENTER key. The DDR displays the FAULT CODES screen, which enables you to select either ACTIVE CODES, INACTIVE CODES or CLEAR CODES.

3. Use the q and Q keys to select ACTIVE CODES. Press the ENTER key.

4. If an active fault code does not exist in TCU memory: The DDR displays the NO ACTIVE CODES screen:

5. If an active fault code exists: The DDR displays the fault code information.

Table B: J1939 Com Link Screen Description

Fault Codes Change ESS Options

Calibration ID Torque Control

Performance Data Component Tests

ESS Trip Data Axle Ratio Options

View ESS Options Change Password


q- - - - S e l e c t i o n s - - - - QF A U L T C O D E S

F A U L T C O D E S

q- - - - S e l e c t i o n s - - - - QA C T I V E C O D E S

J1939 COMMUNICATIONSLINK FAULT

General FaultDescription

FAILURE MODE NOT IDENTIFIABLE

General Description of the FMI

A1

A2

I1

First active fault

Second active fault

First inactive fault

SID:231 J1587 code description =J-1939 Communications Link Fault

FMI:11 Failure mode identifier description

N O A C T I V E C O D E S[ E N T E R ] T O C O N T I N U E

J 1 9 3 9 C O M L I N K F A U L TF A I L U R E M O D E

N O T I D E N T I F I A B L E

qA 1 x x x x S I D : 2 3 1 x x x x F M I : 1 1 Q


50

How to Clear Active and Inactive Fault Codes from TCU Memory

1. Use the q and Q keys to select FAULT CODES from the ZF MERITOR ESS menu.

2. Press the ENTER key. The DDR displays the FAULT CODES screen, which enables you to select either ACTIVE CODES, INACTIVE CODES or CLEAR CODES. Use the q and Q keys to select CLEAR CODES.

3. Press the ENTER key. The DDR displays the CLEAR CODES screen:

4. Use the r and R keys to select [YES]. Press the ENTER key.

5. If you select [NO]: The DDR will return to the FAULT CODES screen.

6. If you select YES: The DDR will display the CODES CLEARED screen:

7. Press the ENTER key to return to the FAULT CODES screen.

8. Press the FUNC key to return to theZF MERITOR ESS screen.

“Performance Data” Option

The PERFORMANCE DATA option contains the following selections. Refer to the glossary at the end of this section for a complete description of the contents of the “Performance Data” list.

r Shift Knob Counts r Solenoid Fault

r ESS Enable r TCU Voltage

r Neutral Switch r Output RPM

r In Gear Switch r Engine RPM

r System Switch r Axle Ratio

r Shift Intent Switch r Axle Ratio Learn

r Break Torque Switch r Transmission Oil Level

r Transmission OilTemperature

1. From the ZF MERITOR ESS screen, use the q and Q keys to select PERFORMANCE DATA.

2. Press the ENTER key. The DDR displays the PERFORMANCE DATA options menu:

3. Use the q and Q keys to scroll through the list.

4. To return to the ZF MERITOR ESS screen press the FUNC key.

F A U L T C O D E S

q- - - - S e l e c t i o n s - - - - QC L E A R C O D E S

C L E A R C O D E SA R E Y O U S U R E ?

Y E S x x x x r Rx x x x [ N O ]

C O D E S C L E A R E D[ E N T E R ] T O C O N T I N U E


q- - - - S e l e c t i o n s - - - - QP E R F O R M A N C E DATA

S H I F T K N O B C T S 8 3 3E S S E N A B L E O NN E U T R A L S W O NI N G E A R S W O F F


51

“Calibration Identification (ID)” Option

1. From the ZF MERITOR ESS screen, use the q and Q keys to select CALIBRATION ID.

2. Press the ENTER key. The DDR displays the CALIBRATION ID menu:

Table C: Calibration Identification Screen Description


“Component Tests” Option

Three selections are available in the COMPONENT TESTS option:

r “Self Test”

r “Reset TCU”

r “Range Solenoids”

1. From the ZF MERITOR ESS screen, use the q or Q keys to select COMPONENT TESTS.

2. Press the ENTER key. The DDR displays the COMPONENT TESTS screen.


“Self Test”

NOTE: When you select SELF TEST the TCU performs both a self-diagnostic test and a test of all ESS system components to verify that they function correctly.

1. From the COMPONENT TESTS screen, use the q and Q keys to select SELF TEST.

2. Press the ENTER key. The DDR displays the SELF TEST screen:

3. When the self test verifies that the TCU and ESS system components function correctly, the DDR displays the SELF TEST SUCCESSFUL screen:


Line 1 Program file

Line 2 Calibration file

Line 3 Transmission serial number

Line 4 Transmission model number

Line 5 Torque limit profile (Contact Meritor’s Customer Service at 800-535-5560 for details.)


q- - - - S e l e c t i o n s - - - - QC A L I B R AT I O N I D

P R O G R A M I D S A X 0 0 1 0 0C A L I D S A X 0 0 1 0 0S / N L B 9 9 0 0 0 0 0 1M O D E L M 0 1 6 F 1 0 C E 1 8T O R Q U E L I M I T I D 0 5


q- - - - S e l e c t i o n s - - - - QC O M P O N E N T T E S T S

C O M P O N E N T T E S T

q- - - - S e l e c t i o n s - - - - QS E L F T E S T E T C

S E L F T E S T S U C C E S S F U L

[ E N T E R ] T O C O N T I N U E


52

“Reset TCU” Test

The RESET TCU test resets the TCU’s parameters. This is similar to turning the ignition key OFF and ON.

1. From the COMPONENT TESTS screen, use the q and Q keys to select RESET TCU.

2. Press the ENTER key. When the TCU parameters are reset, the DDR displays the RESET TCU SUCCESSFUL screen:


“Range Solenoids” Test

The “Range Solenoids” test cycles the range solenoids to verify that they are operating correctly.

1. From the COMPONENT TESTS screen, use the q and Q keys to select RANGE SOLENOIDS.

2. Press the ENTER key. Once the range solenoids have cycled successfully, the DDR displays the RANGE SOLENOIDS SUCCESSFUL screen.


“View ESS” Option

1. From the ZF MERITOR ESS screen, use the q and Q keys to select VIEW ESS OPTIONS.

2. Press the ENTER key. The DDR displays the ESS OPTIONS menu:

Table D: ZF Meritor ESS Options Screen Description


R E S E T T C US U C C E S S F U L


R A N G E S O L E N O I D SS U C C E S S F U L


ESS ENABLE

Turns the system ON or OFF from within the calibration file. Overrides the system switch on the shift knob.

ENG BRK SHIFT

Turns the engine brake (if equipped) ON or OFF during upshifts.

LATE CHANGE EN

Enables you to change from an upshift to a downshift while in NEUTRAL.

2ND CHANCE

Enables you to resume a shift after the three-second “Time Out Sequence” has expired. Refer to Section 1 to read more about this ESS safety feature.

SKIP SHIFT EN

Enables you to skip shift during upshifts or downshifts.


q- - - - S e l e c t i o n s - - - - QV I E W E S S O P T I O N S

E S S E N A B L E O NE N G B R K S H I F T E N O NL A T E C H A N G E E N O N2 N D C H A N C E E N O N


53

“Change ESS” Options

1. From the ZF MERITOR ESS screen, use the q and Q keys to select CHANGE ESS™ OPTIONS.

2. Press the ENTER key. The DDR displays the ENTER PASSWORD screen:

3. Enter the user password. Once the password is accepted, the DDR displays the ESS OPTIONS menu:

4. Use the q and Q keys to select one of the options. Press the ENTER key. The following screen is an example of changing the status of the LATE CHANGE EN option:

5. Use the q and Q keys to select the appropriate ON or OFF status option.

6. Press the ENTER key to change the status of the LATE CHANGE EN option to OFF.

“ESS Trip Data” Options

1. From the ZF MERITOR ESS™ screen, use the q and Q keys to select ESS TRIP DATA.

2. Press the ENTER key. The DDR displays the ESS TRIP DATA screen. Select VIEW to view the shift counts:

3. Press the ENTER key. The DDR displays the ESS TRIP DATA menu:

Table E: Trip Data Screen Description

* Examples of an unsuccessful shift include using the clutch to shift or not completing a shift within the two-second “Time-Out Sequence” while ESS™ is active.

** A manual shift is a shift that you complete when the ESS™ system is inactive or the system is turned OFF.


q- - - - S e l e c t i o n s - - - - QC H A N G E E S S O P T I O N S

E N T E R PA S S W O R D

- - - - - - - -

E S S E N A B L E O NE N G B R K S H I F T O NL A T E C H A N G E E N O N2 N D C H A N C E O N

L AT E C H A N G E E NS E L E C T N E W S TAT U S

q- - - - - - - 0 F F - - - - - - - Q

NUMBER SHIFTS

Number of ESS shifts = 1000

ABORTED SFT CNT

Number of unsuccessful ESS shifts* = 100

MAN SHIFT CNT

Number of manual shifts** = 500


q- - - - S e l e c t i o n s - - - - QE S S T R I P DATA

E S S T R I P DATA

q- - - - S e l e c t i o n s - - - - QV I E W

E S S S H I F T S 1 0 0 0A B O R T S F T C N T 1 0 0N O N - E S S S H I F T S 5 0 0


54

How to Reset “ESS Trip Data”

1. From the ESS TRIP DATA screen, use theq and Q keys to select the RESET option.

2. Press the ENTER key. The TCU resets the shift counters, and the DDR readout displays the RESET SUCCESSFUL screen:

“Axle Ratio” Option

The AXLE RATIO OPTIONS screen enables you to reset axle ratio values by selecting either AXLE RATIO or AXLE RATIO LEARN. The TCU uses the axle ratio value to synchronize engine rpm to road speed.

Table F: Axle Ratio Screen Description

1. From the ZF MERITOR ESS screen, use the q and Q keys to select AXLE RATIO OPTIONS. Press the ENTER key. The DDR displays the AXLE RATIO OPTIONS screen.

2. Press the ENTER key. The DDR displays the PASSWORD screen:

3. Enter the OEM password. When the password is accepted, the DDR displays the AXLERATIO menu:

Entering an Axle Ratio

1. From the SET AXLE RATIO screen, use the q and Q keys to select AXLE RATIO. The DDR displays the INPUT AXLE RATIO screen:

2. Use the numeric keypad to enter an actual axle ratio.

3. Press the ENTER key. The DDR displays the RESET AXLE RATIO screen:

Axle Ratio Enables you to use the DDR numeric keyboard to manually enter the axle ratio value.

Axle Ratio Learn

Enables the TCU to automatically “learn” the axle ratio value.

E S S T R I P DATA

q- - - - S e l e c t i o n s - - - - QR E S E T

S H I F T C O U N T E R R E S E T S U C C E S S F U L



q- - - - S e l e c t i o n s - - - - QA X L E R AT I O O P T I O N S

E N T E R PA S S W O R D

- - - - - - - -

S E T A X L E R AT I O

q- - - - A X L E R AT I O - - - - Q

I N P U T A X L E R AT I O

__._R A N G E 2 . 0 0 - 7 . 9 9

R E S E T A X L E R AT I OA R E Y O U S U R E ?

Y E S x x x x x x x [ N O ]


55

4. Use the r and R keys to select [YES] or [NO]. When the axle ratio is reset, the DDR displays the AXLE RESET SUCCESSFUL screen:

5. This option automatically disables the AXLE RATIO LEARN function. Press the ENTER key to return to the ZF MERITOR ESS AXLE RATIO OPTIONS screen.

Using the “Axle Ratio Learn” Function

1. From the SET AXLE RATIO menu, use the q and Q keys to select RESET AXLE RATIO LEARN.

2. Press the ENTER key. The DDR displays the AXLE RATIO LEARN screen:

3. Use the r and R keys to select [YES] or [NO].

4. If you select the [YES] option, AXLE RATIO LEARN is reset, and the DDR displays the AXLE RATIO LEARN RESET screen.

5. This option automatically disables the AXLE RATIO SET option. Press the ENTER key to return to the AXLE RATIO OPTIONS screen.

“Torque Control” Option

Viewing Engine Torque Control Counters

You can view three torque control counters when you select TORQUE CONTROL from theZF MERITOR ESS screen:

r Total hours

r No Torque Control Hours

r Over Torque Limit Hours

1. From the ZF MERITOR ESS screen, use the q and Q keys to select TORQUE CONTROL.

2. Press the ENTER key. The DDR displays the TORQUE CONTROL COUNTERS menu:

Table G: Torque Control Counters Screen Description


A X L E R AT I O R E S E T[ E N T E R ] T O C O N T I N U E

S E T A X L E R AT I O

q- - - - S e l e c t i o n s - - - - QA X L E R AT I O L E A R N

R E S E T A X L E R AT I O L E A R NA R E Y O U S U R E ?

Y E S x x x x x x x [ N O ]

A X L E R AT I O L E A R NR E S E T


TOTAL HOURS= 1000

Number of hours the TCU has been operating

NO TRQ CTRL HRS = 100

Number of hours the engine torque control features have been disabled

OVER TRQ LMT HRS = 20

Number of hours that engine torque was above the calibrated level


q- - - - S e l e c t i o n s - - - - QT O R Q U E C O N T R O L

T O TA L H O U R S 1 0 0 0N O T R Q C T R L H R S 1 0 0O V E R T Q L M T H R S 2 0


56

“Change Your Password” Option

1. From the ZF MERITOR ESS screen, use the q and Q keys to select change password.

2. Enter your password at the prompt.

3. Press the ENTER key. The DDR will display the ENTER NEW PASSWORD screen:

4. Enter your new password. The DDR will display the CHANGE PASSWORD SUCCESSFUL screen when your new password is confirmed:

5. Press the ENTER key to return to the AXLE RATIO OPTIONS screen.

How to Use the Pro-Link® 9000 DDR to Test ESS™ Components

Open the ESS™ Application

Refer to the procedures in “How to Open the ESS™ System Application” at the beginning of this section.

Ten options are available in the ZF MERITOR ESS application screen. You will use the “Fault Code” and “Performance Data” options to test ESS™ components.

Table H: ZF Meritor ESS™ Application Options

Testing ESS™ Components

NOTE: If a system fault requires you to install a new ESS™ component, first verify that the wiring harness(es) that connects the component to the transmission control unit (TCU) is not pinched, frayed or cut. A damaged wiring harness will cause the TCU to register an active fault for the new component you install. Refer to Section 5 to replace the wiring harness.

Transmission Control Unit (TCU): Fault Code 254

NOTE: ZF Meritor’s ESS™ transmission control unit (TCU) is not serviceable. If a fault exists, replace the TCU.

One fault code applies to this component: Fault Code 254. Refer to Table I below.

Table I: Controller Fault Code 254

* Sub-system Identifier** Failure Mode Indicator

1. To verify that this fault is an active fault, use the q and Q keys to select FAULT CODES from the ZF MERITOR ESS screen.


q- - - - S e l e c t i o n s - - - - QC H A N G E PA S S W O R D

E N T E R N E W PA S S W O R D

- - - - - - - -

C H A N G E PA S S W O R D S U C C E S S F U L


Fault Codes Change ESS Options

Calibration ID Torque Control

Performance Data Component Tests

ESS Trip Data Axle Ratio Options

View ESS Options Change Password

*SID **FMI Description

254 11 Internal Controller Fault


q- - - S E L E C T I O N S - - - QFA U LT C O D E S


57

2. Press the ENTER key. The DDR displays the FAULT CODES screen, which enables you to select either ACTIVE CODES, INACTIVE CODES or CLEAR CODES. Use the q and Q keys to select ACTIVE CODES.

3. Press the ENTER key. If the DDR displays the following CONTROLLER FAULT screen, there is an active fault in the TCU. Contact Meritor’s Customer Service Center at 800-535-5560 for assistance. If you are instructed to replace the TCU, refer to Section 5 for instructions.

ESS™ Shift Knob: Fault Code 227

NOTE: The ESS™ shift knob is not serviceable. If a fault exists, replace the shift knob.

Fault Code 227 applies to the ESS™ shift knob and includes three fault code descriptions. Table J.

Table J: Shift Knob Fault Code 227




3. Press the ENTER key. If the DDR displays the SHIFT KNOB FAULT screen (refer to the sample screen below), an active fault exists in the shift knob. Refer to “How to Test the Shift Knob Using the SHIFT KNOB STATUS Option in the Performance Data List.”


227 2 Shift knob data erratic, intermittent or incorrect

227 3 Shift knob voltage above normal or shorted high

227 4 Shift knob voltage below normal or shorted low

FA U LT C O D E S- - - S E L E C T I O N S - - -

A C T I V E C O D E S

C O N T R O L L E R FA U LTFA I L U R E M O D E


qA O I S I D : 2 5 4 F M I : 1 1 Q


q- - - - S e l e c t i o n s - - - - QFA U LT C O D E S

FA U LT C O D E S


S H I F T K N O B FA U LTV O LTA G E A B O V E N O R M A L

qA O I S I D : 2 2 7 F M I : 3 Q


58

How to Test the Shift Knob Using the SHIFT KNOB STATUS Option in the Performance Data List

The SHIFT KNOB STATUS option allows you to verify that the shift knob functions correctly.


2. Press the ENTER key. The DDR displays the PERFORMANCE DATA options screen.

3. If necessary, use the q and Q keys to select the SHIFT KNOB STATUS option.

4. Verify shift knob counts: Refer to Table K to verify that the switches on the shift knob indicate the correct counts.

5. If the shift knob counts do not correspond to those listed in Table K:

r Check the wiring harness.

r Check the shift knob independently of the wiring harness.

r Replace the shift knob. Refer to Section 5 for instructions.

Table K: Shift Knob Counts



S H I F T K N O B C T SE S S E N A B L EN E U T R A L S WI N G E A R S W

Shift Knob Counts

System Switch Status

Shift Intent Switch Status

Break Torque Switch Status

469-484 Off (up) Off (up) Off

469-484 Off (up) Off (up) On (full up)

546-562 Off (up) On (down) Off

546-562 Off (up) On (down) On (full down)

662-676 On (down) Off (up) Off

727-742 On (down) Off (up) On (full up)

827-840 On (down) On (down) Off

933-942 On (down) On (down) On (full down)


59

ESS™ High and Low Range Shift Solenoids: Fault Codes 35 and 36

NOTE: ESS™ high- and low-range shift solenoids are not serviceable. If a fault exists, replace the solenoids.

Fault Codes 35 and 36 apply to ESS high- and low-range shift solenoids. Each fault code includes two fault code descriptions. Table L.

Table L: Fault Codes 35 and 36




3. Press the ENTER key. If the DDR displays the RANGE SHIFT SOLENOID screen (refer to the sample screen below), an active fault exists in the shift knob. Refer to “How to Test the Shift Knob Using the HIGH SOLENOID and LOW SOLENOID Options in the Performance Data List.”

How to Test the Shift Knob Using the HIGH SOLENOID and LOW SOLENOID Options in the Performance Data List

The HIGH SOLENOID and LOW SOLENOID options enable you to verify that the high- and low-range solenoids function correctly.


2. Press the ENTER key. The DDR displays the PERFORMANCE DATA screen.

3. If necessary, use the q and Q keys to select the SOLENOID FAULT option simultaneously.

4. Verify that the low range and high range solenoids work correctly: If a solenoid fault exists, use the COMPONENT TESTS option to test both solenoids. Replace a solenoid only after testing it with a volt-ohm meter.


35 3 High range solenoid voltage above normal or shorted high

35 4 High range solenoid voltage below normal or shorted low

36 3 Low range solenoid voltage above normal or shorted high

36 4 Low range solenoid voltage below normal or shorted low



FA U LT C O D E S


L O W R A N G E S O L E N O I DV O LTA G E A B O V E N O R M A L

qA O I S I D : 3 6 F M I : 3 Q



S O L E N O I D FA U LTT C U V O LTA G EO U T P U T R P ME N G I N E R P M


60

ESS™ Switch Assembly (Neutral and In Gear Switches): Fault Code 226

NOTE: The ESS™ neutral switch and in gear switch are not serviceable. If a fault exists in either switch, replace the entire switch assembly.

The neutral switch and the in gear switch are individual components built into a single housing called the ESS™ switch assembly. Table M.


2. Press the ENTER key. The DDR displays the FAULT CODES screen, which enables you to select either ACTIVE CODES or CLEAR CODES. Use the q and Q keys to select ACTIVE CODES.

3. Press the ENTER key. If the DDR displays the NEUTRAL/IN GEAR screen (refer to the sample screen below), an active fault exists in the shift knob. Refer to “How to Test the Neutral Switch and In Gear Switch Using the NEUTRAL SW and IN GEAR SW Options in the Performance Data List.”

How to Test the Neutral Switch and In Gear Switch Using the NEUTRAL SW and IN GEAR SW Options in the Performance Data List

The NEUTRAL SW and IN GEAR SW options enable you to verify that these switches function correctly.


2. Press the ENTER key. The DDR displays the NEUTRAL SW and IN GEAR SW options screen.

3. If necessary, use the q and Q keys to select the NEUTRAL SW and IN GEAR SW options simultaneously.

4. Verify that the neutral switch and in gear switch operate correctly: Put the transmission in and out of gear while checking the display. The values must correspond to those listed in Table M.

5. If either the neutral switch or in gear switch values do not correspond to those in Table M: Replace the entire switch assembly. Refer to Section 5 for instructions.

Table M: Fault Code 226




FA U LT C O D E S


N E U T R A L / I N G E A R S W I T C HFA I L U R E M O D E


qA O I S I D : 2 2 6 F M I : 1 1 Q *SID **FMI Description

226 11 ESS™ Switch Assembly Fault



N E U T R A L S W I T C HI N G E A R S W I T C HS Y S T E M S W I T C H

S H I F T I N T E N T S W I T C H


61

ESS™ Vehicle Speed Sensor (VSS): Fault Code 191

NOTE: The ESS™ vehicle speed sensor (VSS) is not serviceable. If a fault exists, replace the speed sensor.

Fault Code 191 applies to the ESS vehicle speed sensor (VSS) and includes three fault code descriptions. Refer to Table N below.

Table N: Fault Code 191



2. Press the ENTER key. The DDR displays the FAULT CODES screen, which enables you to select either ACTIVE CODES or CLEAR CODES. Use the q and Q keys to select ACTIVE CODES.

3. Press the ENTER key. If the DDR displays the SPEED SENSOR FAULT screen (refer to the sample screen below), an active fault exists in the shift knob. Refer to “How to Test the Vehicle Speed Sensor (VSS) Using the ‘Output RPM’ Option in the Performance Data List.”

How to Test the Vehicle Speed Sensor (VSS) Using the “Output RPM” Option in the Performance Data List

The “Output RPM” option enables you to verify that the vehicle speed sensor operates correctly.


2. Press the ENTER key. The DDR displays the OUTPUT RPM options screen.

3. If necessary, use the q and Q keys to select the OUTPUT RPM option.

4. Press the ENTER key.

5. Verify that the vehicle speed sensor operates correctly: Drive the vehicle in “direct drive.” Compare OUTPUT RPM and ENGINE RPM values to those listed in Table N. The vehicle speed sensor is operating correctly if both of these values are equal.

6. If the OUTPUT RPM and ENGINE RPM values do not equal one another: Replace the vehicle speed sensor. Refer to Section 5.


191 2 Speed sensor signal erratic, intermittent or incorrect

191 3 Speed sensor voltage above normal or shorted high

191 4 Speed sensor voltage below normal or shorted low



FA U LT C O D E S


S P E E D S E N S O R FA U LTDATA E R R AT I C O R I N C O R R E C T

qA O I S I D : 1 9 1 F M I : 2 Q



O U T P U T R P M 0E N G I N E R P M 0A X L E R AT I O 2 . 8 0A R AT I O L E A R N O N


62

Glossary

Performance Data List Options

Shift Knob Status Verifies that the system switch and shift intent switch operate correctly. Refer to “ESS™ Shift Knob: Fault Code 227” in this section.

Engine RPM Specifies engine speed.

TCU Voltage Specifies the transmission control unit’s (TCU) power (voltage) supply.

Axle Ratio Specifies axle ratio used by the transmission control unit (TCU).

Trans Oil Level Specifies the transmission oil level. If a sensor is not installed, the “Trans Oil Level” option will be labeled “N/A.”

Trans Oil Temp Specifies transmission oil temperature. If a sensor is not installed, the “Trans Oil Temp” option will be labeled “N/A.”

ESS Enable ON ESS™ system activated at the TCUOFF ESS™ system not activated at the TCU

Neutral Switch ON Transmission in NEUTRALOFF Transmission not in NEUTRAL

In Gear Switch ON Transmission in gearOFF Transmission not in gear

System Switch ON (Slide switch UP)

OFF (Slide switch DOWN)

Activates the ESS™ system at the shift knobDeactivates the ESS™ system at the shift knob

Shift Intent Switch Toggle the rocker switch UP

Toggle the rocker switch DOWN

Activates the shift intent switch to signal the TCU that the next shifts will be UPSHIFTS

Activates the shift intent switch to signal the TCU that the next shifts will be DOWNSHIFTS

Break Torque Switch Press the rocker switch DOWN to end of travel or UP to end of travel

Rocker switch is not pressedDOWN to end of travel or UP toend of travel

Activates break torque feature

Break torque feature is not activated

Axle Ratio Learn Specifies the method used by the transmission control unit (TCU) to calculate axle ratio. This ratio can be “learned” by the TCU, or you can enter an axle ratio into the diagnostic data reader (DDR).

“Learned” by TCU

User enters axle ratio into DDR

DDR displays “Enabled”DDR displays “Disabled”

Low Solenoid ON (Activated)

OFF (Not activated)

Vehicle in LOW rangeVehicle in HIGH range

High Solenoid ON (Activated)

OFF (Not activated)

Vehicle in HIGH rangeVehicle in LOW range

Section 4

Wiring Diagram and Component Overview

63

Section 4Section 3

ZF M

ER

ITO

R T

.C.U

. 30 P

IN

LO

W

SO

LE

NO

ID

A B A B

Fu

ncti

on

AN

ALO

G S

UP

PLY

(+

5V

)

AN

ALO

G S

W S

IGN

AL

HIG

H S

OLE

NO

ID

LO

W S

OLE

NO

ID

IN G

EA

R S

IGN

AL

NE

UT

RA

L S

IGN

AL

SW

ITC

HE

D IG

NIT

ION

(12V

)

VE

HIC

LE

SP

EE

D S

EN

SO

R

CA

N H

IGH

CA

N L

OW

CA

N S

HIE

LD

J1708 +

J1708 -

CH

EC

K T

RA

NS

MIS

SIO

N P

IN

+ B

AT

TE

RY

- B

AT

TE

RY

GN

D

Pin

No

.

J3

K2

B2

B1

G2

G1

A2

B3

D1

D2

D3

E1

E2

E3

A1

A3

K3

AB

CD

EF

AB

CD

EF

AB

C

AB

C

AB

AB

J-1

939

J-1

708

A B

D C B A

D C B A

AB

AB

AB

AB

+ 1

2 V

OLT

SW

ITC

HE

D

(IG

NIT

ION

)

+ B

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HIG

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CL

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A"B

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EQ

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ST

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R2

68

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33.2

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SH

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ION

SH

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N I

N"U

PS

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SIT

ION

UP

/DO

WN

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/OF

F

R0

10.0

K

DC

BA

DC

BA

BA

BA

GO

EM

LE

VE

RH

AR

NE

SS

ES

CR

UIS

E H

AR

NE

SS

(O

PT

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AL)

— S

HIF

T K

NO

B

WIR

ING

HA

RN

ES

S

CO

MM

AN

D H

AR

NE

SS

— S

HIF

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NO

B

SO

LE

NO

ID A

SS

EM

BL

Y

SO

LE

NO

ID A

SS

EM

BL

Y

SW

ITC

H A

SS

EM

BL

Y S

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WN

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FR

EE

ST

AT

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UT

RA

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IGN

AL

SP

EE

D S

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SS

EM

BL

YA B

OE

M P

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SE

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WIT

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pen

PA

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WIT

CH

No

rmall

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losed

OE

M S

HIF

TK

NO

B H

AR

NE

SS

GR

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ND

Section 4

Wiring Diagram and Component Overview

64

Sh

ift

Kn

ob

Sp

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Sen

so

rA

ssem

bly

Neu

tral/

In G

ear

Sw

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Assem

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ON

OFF

OFF

OV

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AV

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UP

UP

DO

WN

OV

ER

TR

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DO

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UP

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42.3

k–44.1

k o

hms

57.0

k–59.4

k o

hms

24.5

k–25.5

k o

hms

9.8

k–10.2

k o

hms

123.8

k–128.8

k o

hms

91.2

k–95.0

k o

hms

BB

A

BA

A

ADC

BA

11

–2

1 o

hm

s

B

VIE

W A

-A

VIE

W B

-B

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ST

M

RE

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NC

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EA

SU

RE

D A

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OS

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INS

)

AB

VIE

W A

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k–3

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oh

ms

RE

SIS

TA

NC

E(M

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D A

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INS

)

AB

A A

AD

CB

CC

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-C

A B C D E F G H J K

1

2

3

A B C D E F G H J K

RE

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PIN

SIN

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(FR

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ss

Section 5Removal and Installation

65


WARNING

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.


Take care when you use Loctite

®

to avoid serious personal injury. Follow the manufacturer’s instructions to prevent irritation to the eyes and skin. If Loctite

®

gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a doctor as soon as possible.

TCU Removal

Use a 1/4-inch socket to remove the fastener that secures the thirty-pin TCU connector to the TCU.

Remove the thirty-pin TCU connector from the TCU.

Step 1

Use a 1/4-inchsocket.

Step 2


66

Use a 7/16-inch socket to remove the four 1/4-inch-20 x 2.75-inch fasteners and flat washers that secure the TCU to the mounting plate.

Return the TCU to ZF Meritor for a core credit. Call Meritor’s Aftermarket Services in Florence, Kentucky, at 888-725-9355 for assistance.

Step 3

Step 4


67

TCU Installation

If necessary, obtain a replacement TCU from Meritor’s Aftermarket Services in Florence, Kentucky, at 888-725-9355.

Use a socket to fasten the TCU to the mounting plate with four 1/4-inch-20 x 2.75-inch fasteners and flat washers. Tighten the fasteners to 10 lb-ft (13 N•m).

Step 1

Step 2

Insert the thirty-pin TCU connector into the TCU. Secure the thirty-pin TCU connector to the TCU. Use a 1/4-inch socket to tighten the fasteners to 100 lb-in (11.3 N•m).

Step 3

Step 4

Use a 1/4-inchsocket.


68

Shift Knob Removal

Use a Phillips head screwdriver to remove the screw that secures the skirt to the shift knob housing.

Separate the skirt from the shift knob assembly.

Step 1

SHIFTKNOB


SKIRT

Step 2

SHIFTKNOB

SKIRT

Disconnect the electrical connectors at the base of the shift knob.

Loosen the jam nut at the base of the shift knob with a 3/4-inch wrench.

Step 3

PAUSE RESUME

SET

SHIFTKNOB

ELECTRICALCONNECTORS

Step 4

SHIFT KNOB

JAM NUT

3/4" WRENCH


69

Remove the shift knob from the lever by turning the shift knob COUNTERCLOCKWISE.

Remove the shift knob skirt.

Step 5

PAUSE RESUME

SETSHIFTKNOB

Step 6

SKIRT

JAM NUT


70

Shift Knob Installation

Slip the shift knob skirt onto the shift lever. Install the shift knob on the lever by turning the shift knob CLOCKWISE.

Step 1

SKIRT

JAM NUT

Step 2

Position the knob as desired. Use a 3/4-inch wrench to tighten the jam nut at the base of the shift knob.

Connect the three electrical connectors at the base of the shift knob to the wiring harness connectors by pushing them together.

Step 3

SHIFT KNOB

JAM NUT

3/4" WRENCH

Step 4

PAUSE RESUME

SET

SHIFTKNOB

ELECTRICALCONNECTORS


71

Connect the skirt to the shift knob. Use a Phillips head screwdriver to tighten the fastener that secures the skirt to the shift knob housing.

Step 5

SHIFTKNOB


SKIRT


72

Wiring Harness Removal

Disconnect the TCU connector. Disconnect the J-1939 connector.

Step 1

TCU

Step 2

J-1939

Disconnect the shift knob connector. Disconnect the wiring harness from the vehicle speed sensor (VSS).

Step 3

SHIFT KNOB

Step 4

VEHICLESPEEDSENSOR


73

Disconnect the OEM power connector. Disconnect the harness connector from the neutral position switch connector.

Step 5

OEM

Step 6


Disconnect the J-1708 connector. Disconnect the solenoid connectors.

Step 7

J-1708

Step 8

HIGH RANGESOLENOID

LOW RANGESOLENOID


74

Remove the wiring harness from the hold-down clips. Remove the wiring harness.

Step 9

HOLD-DOWNCLIP


75

Wiring Harness Installation

Connect the wiring harness connectors to the HIGH and LOW range cylinder solenoids. Connect one yellow and one red wire to the HIGH solenoid. Connect one blue and one red wire to the LOW solenoid.

Connect the wiring harness to the J-1708 connector.

Step 1

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 2

J-1708

Connect the wiring harness to the switch assembly.

Connect the wiring harness to the OEM power connector.

Step 3


Step 4

OEM


76

Connect the wiring harness to the shift knob connector.

Connect the wiring harness to the J-1939 connector.

Step 5

SHIFT KNOB

Step 6

J-1939

Connect the wiring harness to the vehicle speed sensor.

Install the wiring harness into the hold-down clips.

Step 7

VSS

Step 8


77

Connect the wiring harness to the TCU.

Step 9

TCU


78

Top Cover Removal

Remove the wiring harness. (Refer to “Wiring Harness Removal” in this section.)

Clean the top cover housing before removal.

Step 1

Step 2

Clean topcover housing.

Remove the neutral position switch sensor from the top cover housing.

Use a magnet to remove the neutral position switch sensor actuator pin from the bore in the top cover housing.

Step 3

O-RING

NEUTRALPOSITION SWITCHSENSOR 3/4-16 THREAD1-1/16" OPENEND WRENCH

Step 4

MAGNET

NEUTRALPOSITIONSWITCHACTUATOR PIN


79

Remove the shift tower. For a standard cover, use tape to protect the detent springs if no dust cover was installed.

Use a 9/16-inch socket to remove the sixteen3/8-16 top cover housing capscrews.

Step 5

TAPE DETENT SPRINGS

Step 6

9/16" SOCKET

Remove jack hole plugs. Install two of the 3/8-16 capscrews into the threaded jack holes.

Step 7

JACK HOLE PLUGS

Step 8

3/8-16JACKSCREW

JACKHOLE


80

Use a hand or air ratchet to alternately turn the two 3/8-16 jackscrews until the top cover is separated from the case.

Remove the top cover housing from the transmission case assembly.

Step 9

9/16" JACKSCREW

Step 10

TOPCOVER

Use a scraper to remove all sealant from the surface of the top cover housing and transmission case assembly. The sealant you remove must not fall inside the transmission. Clean the mounting surface with Loctite

®

Safety Sealant.

Step 11


81

Top Cover Installation

Apply Loctite

®

Ultra Grey Adhesive/Sealant #18581 (Meritor part No. 2297-A-7021) onto the transmission case assembly.

Place the top cover shift shafts in the neutral position. Place the shift collars in the neutral position. Install the top cover and align and engage the forks with the sliding clutch collars.

Step 1

FIVE HOLESSURROUNDED BYA CONTINUOUS1/8" BEADOF SEALANT

TRANSMISSION CASE

1 2 3 4

5

Step 2

TOPCOVER

DOWEL

Clean mounting capscrew threads. Apply Loctite

®

#242 (Meritor part number 2297-V-2430) or equivalent to the threads.

Install the sixteen 3/8-16 mounting capscrews and washers for the top cover housing. Use a torque wrench to tighten the capscrews to 25-35 lb-ft(34-47 N•m).

Step 3

1. Clean threads.

2. Apply Loctite® #242.

Step 4

3/8-16 CAPSCREW


82

Install the jack hole plugs. Install the neutral position switch sensor. Use a torque wrench to tighten the sensor to 150-210 lb-in (17-24 N•m).

Step 5

JACK HOLE PLUGS

Step 6

O-RING


Install the neutral position switch sensor actuator pin into the bore in the top cover housing.

Remove the tape from the detent springs. Install the shift tower.

Step 7

MAGNET

NEUTRALPOSITIONSWITCHACTUATOR PIN

Step 8

TAPE DETENT SPRINGS


83

Overhauling the Top Cover HousingStandard and Forward Positions

NOTE: Only features unique to the ESS™ top cover are shown in this section. Refer to Maintenance Manual No. 26A, Nine-Speed, Ten-Speed and Thirteen-Speed Transmissions, for overhaul procedures not covered in this manual. To order a copy of this publication, call Meritor’s Customer Service Center at 800-535-5560.

Step 9

STANDARD POSITION COVER FORWARD POSITION COVER

INDICATESX-BAR

STANDARD POSITION COVER — X-BAR

INDICATESX-BAR

FORWARD POSITION COVER — X-BAR


84

Range Cylinder Solenoid Removal

Disconnect the two range solenoid connectors. Remove the two Allen-head bolts that secure either the HIGH or LOW range cylinder solenoid, depending on which solenoid you are replacing.

Step 1

HIGH RANGESOLENOID

LOW RANGESOLENOID

Step 2

RANGECYLINDERSOLENOIDBOLTS

5/32"ALLENWRENCH

Remove either the HIGH or LOW range cylinder solenoid from the range housing. (The low side of the range housing is illustrated.)

Step 3


O-RINGS


85

Range Cylinder Solenoid Installation

Lubricate the new range cylinder solenoid O-rings with Dow Corning® No. 111 Silicone Grease or equivalent. Install the O-rings onto the replacement range cylinder solenoid.

Install the range cylinder solenoid into the range housing. Use an Allen wrench to install the two Allen-head bolts that secure the range cylinder solenoid. Tighten the bolts to 45-55 lb-in(5-6 N•m).

Engage the range cylinder solenoid connector.

Step 1

O-RINGS


Step 2


5/32"ALLENWRENCH

Connect the two solenoid connectors.

Step 3

HIGH RANGESOLENOID

LOW RANGESOLENOID


86


Switch Assembly Removal

Disconnect the harness connector from the neutral position switch connector.


Step 1


Step 2



Step 3

O-RING



87

Switch Assembly Installation

Install the neutral position switch sensor. Use a torque wrench to tighten the sensor to 150-210 lb-in (17-24 N•m).

Connect the wiring harness connector to the neutral position switch connector.

Step 1

O-RING


Step 2



88

Vehicle Speed Sensor Removal

Use a one-inch wrench to remove the speedometer pickup sensor.

Step 1

1" WRENCH

Vehicle Speed Sensor Installation

Install the O-ring on the speedometer pickup sensor.

Use a one-inch wrench to install the speedometer pickup sensor. Use a torque wrench to tighten the sensor to 15 lb-ft (20 N•m).

Step 1

SPEEDOMETERPICKUP SENSOR

O-RING

Step 2

1" WRENCH


89

Neutral Check Shaft Removal

Remove the top cover. Refer to “Top Cover Removal” in this section.

Press and hold the spring-loaded neutral check shaft and remove the shift shafts.

Step 1

TOPCOVER

Step 2

After you remove all of the shift shafts, remove the neutral check shaft from the top cover housing.

Remove the neutral check shaft spring from the top cover housing.

Step 3

NEUTRAL CHECK SHAFT

Step 4

NEUTRAL CHECK SHAFT



90

Neutral Check Shaft Installation

Install the neutral check shaft spring into the top cover housing. Install the neutral check shaft into the top cover housing.

Press and hold the spring-loaded neutral check shaft. Install the shift shafts.

Step 1

NEUTRAL CHECK SHAFT


Step 2

Install the top cover. Refer to “Top Cover Installation” in this section.

Step 3

TOPCOVER


91

Range Cylinder Removal

Step 4

Use a 7/16-inch socket to remove the two 7/16-inch air filter/regulator assembly capscrews.

Remove the air filter/regulator assembly.

Step 1

7/16"SOCKET

AIR FILTER/REGULATORASSEMBLY

Step 2

7/16"CAPSCREW


92

Remove the air filter/regulator O-ring. Use a 5/32-inch Allen wrench to remove the four Allen-head bolts that secure the two range cylinder solenoids.

Step 3

AIRFILTER/REGULATORO-RING

Step 4


5/32"ALLENWRENCH

Remove the range cylinder solenoids. Use a 9/16-inch wrench to remove the four 3/8-16 range cylinder cover bolts.

Step 5


O-RINGS

Step 6

9/16"WRENCH


93

Remove the range cylinder cover. Remove the large and small O-rings from the range cylinder cover.

Step 7

RANGECYLINDER COVER

Step 8

LARGE O-RING

SMALL O-RING

RANGE CYLINDER COVER

Use a socket to remove the 11/16-inch range cylinder piston nut.

Remove the range cylinder piston housing.

Step 9

RANGE CYLINDERHOUSING

RANGECYLINDERPISTON

11/16" SOCKET

Step 10

RANGE SHIFTSHAFT



94

Remove the range shaft O-ring from inside of the range housing shaft bore.

Remove the piston from the housing.

Step 11

Step 12

Remove the range cylinder piston O-ring.

Step 13

RANGE CYLINDERPISTON O-RING


86


Switch Assembly Removal

Disconnect the harness connector from the neutral position switch connector.


Step 1


Step 2



Step 3

O-RING



96

Install the range shift shaft nut with an 11/16-inch socket. Use a torque wrench to tighten the nut to 35-50 lb-ft (47-68 N•m).

Lubricate the large and small O-rings with Dow Corning #111 Silicone Grease or equivalent. Install the range cylinder cover O-ring and the smaller O-ring.

Step 5


RANGECYLINDERPISTON

11/16" SOCKET

Step 6

LARGEO-RING

SMALLO-RING

Install the range cylinder cover. Clean the capscrew threads. Apply Loctite

®

#242 (Meritor part number 2297-V-2430) or equivalent to the capscrew threads. Use a torque wrench to tighten the four 3/4-16 capscrews to 35-45 lb-ft(47-61 N•m).

Lubricate the range cylinder solenoid O-rings with Dow Corning #111 Silicone Grease or equivalent.

Step 7

1. Clean threads.

2. Apply Loctite® #242.

Step 8

O-RINGS



97

Install the range cylinder solenoids onto the range housing.

Use a 5/32-inch Allen wrench to install the four range cylinder solenoid bolts. Tighten the bolts to 50 lb-in (6 N•m).

Step 9


O-RINGS

Step 10


5/32"ALLENWRENCH

Lubricate the air filter/regulator O-ring with Dow Corning #111 Silicone Grease or equivalent. Install the O-ring.

Use a 7/16-inch wrench to install the two air filter/regulator capscrews. Use a torque wrench to tighten capscrews to 10-12 lb-ft (13.6-16 N•m).

Step 11

Step 12

7/16"CAPSCREW


98

Torque Table

* Requires a new application of Loctite

®

242 (Meritor part number 2297-V-2430) or equivalent on threads.

Components Fastener Sizes lb-in lb-ft N

N

m

Speedometer pickup sensor — 150-210 — 17-24

Neutral interlock sensor — 150-210 — 17-24

Detent threaded plug* — — 20-25 27-34

Air filter/regulator fasteners 1/4 x 20 85-115 — 10-13

Solenoid assembly 1/4 x 20 50 — 6

HIGH/LOW range cylinder housing cover 3/8 x 16 x 2-3/4 — 35-45 47-61

Range cylinder piston shift shaft 7/16 x 20 — 35-50 47-68

HIGH/LOW range piston housing threaded plugs

— — 10 13

Shift tower to top cover housing 3/8 x 16 — 35-45 47-61

Top cover housing to main case* 3/8 x 16 x 1-1/4 — 25-35 34-47

Rocking lever assembly pin to top cover housing*

1/2 x 20 — 35-45 47-61

Oil scoop to top cover housing 1/4 x 20 x 1/2 — 10-12 13-16

Shift fork to shift rail 7/16 x 20 — 35-45 47-61

ZF Meritor, LLC

22021 Skyway Church RoadMaxton, NC 28364 USA800-535-5560www.meritorauto.com

Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. ZF Meritor, LLC, reserves the right to revise the information presented or discontinue the production of parts described at any time.

f

Copyright 1999 Maintenance Manual No. MM-9850ZF Meritor, LLC Revised 6-99All Rights Reserved Printed in the USA 16579/24240

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